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FOCS Engine Ser
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CS Engine Series
- Every attempt has been made to present within this service manual, accurate and up to date technical
information.
However, development on the LOMBARDINI series is continuous.
Therefore, the information within this manual is subject to change without notice and without obligation.
- The information contained within this service manual is the sole property of LOMBARDINI.
As such, no reproduction or replication in whole or part is allowed without the express written permission of
LOMBARDINI.
Information presented within this manual assumes the following:
1- The person or people performing service work on LOMBARDINI series engines is properly trained and
equipped to safely and professionally perform the subject operation;
2 - The person or people performing service work on LOMBARDINI series engines possesses adequate hand and
LOMBARDINI special tools to safely and professionally perform the subject service operation;
3 - The person or people performing service work on LOMBARDINI series engines has read the pertinent
information regarding the subject service operations and fully understands the operation at hand.
- This manual was written by the manufacturer to provide technical and operating information to authorised
LOMBARDINI after-sales service centres to carry out assembly, disassembly, overhauling, replacement and
tuning operations.
- As well as employing good operating techniques and observing the right timing for operations, operators must read
the information very carefully and comply with it scrupulously.
- Time spent reading this information will help to prevent health and safety risks and financial damage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the
operating phases.
A KOHLER COMPANY
Manuale officina FOCS cod. 1.5302.350 7% ed rev. 06 -3-
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
CUS ЕО
AY Tmimeba | 1-5302-351 50563 7° 6 04-90 15.03.2008 008
- 4 - FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06
© KOHLER
This manual contains pertinent information regarding the repair of LOMBARDINI water-cooled, indirect injection Diesel
engines type LDW 502-602-903-1204-1204/T e LDW 702-1003-1404: updated March 15", 2006.
CHAPTER INDEX
1 GENERAL REMARKS AND SAFETY INFORMATION ............... eee. eeesmeernernacrcenncenraaneaaneeanenenanm—e Pag. 9-11
GENERAL SAFETY DURING OPERATING PHASES ……...…….ereccrsereeee serre eee eee een ar ere nee race nee eee are r eee serre rare cessera 11
GENERAL SERVICE MANUAL NOTES …….........£ecrseeeeeneeereeemerere ne ere rene eere cena e ere nee e a eee eee eee e eee e eee eee eee ere eee rene eee 9
GLOSSARY AND TERMINOLOGY ..….....…...…eerrcrecerereee an seeee ee eee rene aa eee eee een een ae eee eee eee ee eee e eee eee eee e near eee ae eee eee nee eee 9
SAFETY AND ENVIRONMENTAL IMPACT …..........……erscccecceeerreee een ereaere crane sera ne ea ne ere eee nana eee e eee near eee e encens 11
SAFETY AND WARNING DECALS …...........…cessecececenererere eee er esere cena nr ere ee ee are ne eee e na rasee eee ne een eee near e area e naar a ere ce CEA 10
SAFETY REGULATIONS ..….......….erccceecerererrereenanereere eee anse ree eee na renee eee mean rene eee ee eee eee aan eee eee eee eee eee 10-11
WARRANTY CERTIFICATE .….….......…..ccccrsrererecenererree cena eneer ee names eee e eee ar eee ee eee eee ee eee es eee eee ere eee ee nana area e naar cesse eee 9
2 TECHNICAL INFORMATION ...........…....….....…+eccseccreccee creer ere e crane n ecran e sara nn annee rene rene ane nan crane een se nca een een 12-23
MANUFACTURER AND ENGINE IDENTIFICATION L..........esseeeeesecee ee seeee cer erre cam aaeee mere nee near recenser rene eee e areas 14-15
OVERALL DIMENSION .…...........…ersccececererereeeeeaerere race nee rere eee e ne ree rence near e eee e serre eee aa ea rence ee er eee eee rene eee 21-23
PERFORMANCE DIAGRAMS Leese erate as eee e cer area e area areas eee eee eee essence ens 18-20
TECHINICAL SPECIFICATIONS …............ecceceseeeeeererre een eeeee eee ee eee eee eee ner e nee e serre nee eee ee eee eee eee en eee eee eee eee 16-17
TROUBLE SHOOTING TT 12-13
3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ...........oi secs cesser r annee EEG 24-27
ACEA Regualtions - АСЕА SEQUENCES …...............…......reecesereeeererrre ne ssere ee erer ee aaer eee serre eee recense eee eee ere near eee serrer 25
API / MIL Sequence ...................eeeeeeeeciccrecerrer eee eeee e eee re reee eee areeeerereereenareaeerereeretenerecereecerteeececeeR rece tR e cereev erecta anna 25
COOLANT ............eeeeeaeeieeoerenereeeoneeneseeeceeenenssseseeremevnesserervs;VEErEEEECNECEEECEECErrrErEFECCFrrrrE FECC NrErrEEEFEErrCEEEFECRFrrrrECECRErrrE EFE CErECECEFECTA 27
SO [07 [0 ST 27
International specifications ......................-e.eeereeereeererie recorre errar e na ea a seen e area nana e acer eee e area nana ea seen eee nana casa ce nana 25
LUBRICANT ..….........…..cccecccrrrrree cena enren cena ner eee ee mener eee ee een area eee eee eee eee eee eee eee eee see eee eee e area eee cena e eee nee 25
PRESCRIBED LUBRICANT .......….cccrssrrreeeenererree cena raser nee name rene ee een e serre cena rare eee a are nee eee r eee e eee e naar e eee eee eee 26
ROUTINE ENGINE MAINTENANCE -.............eeereeecccececereneeececerensseseceoerevsessseeenenesesesseerems=sassseese5nvresseeEESNATENECEEEFOTEEEEEEEE CN rEEOCOS 24
SAE Classification RP 25
4 DISASSEMBLY / REASSEMBLY ........…........…...…..…….vercreecrer crane rene rene rene rene ne rene rene nee nana rene sance en eee aaa 28-65
Air filter SUD PO | TT TO eence 30
Air restriction SWItCN ..............…...…ereecreeeeee er eeeee ae eer rene re recenser eee eee rene se eee ee rare serre ee eee eee eee eee eee eee eee eee e rare 29
Alternator/Cooling fan belt drive ….….….........….......……rreeceresserene era rareree nana serre eee nee eee nee a near recenser recense eee enr aeen eee eae eeees 33
Big end DEaring ….....................erreeeeereeree ne rere eee see ee ee ae ere ne sa eee e eee eee eee eee seen e eee e eee eee eee eee rare eee eee eee eee eee eee eee ee 58
Camshaft journals and housings - DiMENSIONS …................…...rreeeeseeeeeeerrer ce aner eee see re ce are eee ea ere eee e ere e eee essence 47
Camshaft lobe Measurement ….….............….…....….ccrerereeeeereeee serre eee rre ce ne aeree eee een een rer e eee eee eee eee rare eee serre ee aan aen ec 47
Camshaft timing - Belt ReassemDly …..............….....…cecrerrreneeeeee ne erere enr rer cena serre en re nee ere eee ee ee eee eee eee eee eee e eee e ane eee eee 37
Camshaft timing - Belt Tightening and Fastening .……....…............….rrereeesereeeererere ne se ere career rene aa eee ee eee ee eee eee sara ee ec 38
Camshaft timing - Belt tightening tOol …..….................eceseereeereere een seee eee eee nee aa ere nee ere eee eee aa ere eee ere eee eee asser nas 38
Camshaft timing pulley - Disassembly/ASSemDlY …….....…........…….rccrrrserreecenerercee cena raaren cena as eee eee e area eee cena e era eee e eee aenaaas 37
Camshaft timing pulley - Reference marKS .…..….......….....…...rrereccreeceene serre eee eere caen ere near eee eee ee ee aa ere eee ere eee eee rare nas 37
Camshaft, disassemDly PR 46
Camshaft, journal and housing measurement .…......…......…...........eeesereeeeeerer cer reeeeneere een rer een ser e ea ee eee eee recense e een een 46
Central main bearing CAPS ….............…....……recereeeeceneereeeneere eee eee r eee eee een eaee eee eee ee are r eee seen eee eee eee ea eee area rare cesse ea 60
Check the clearances between the bearings and the journal... eee 60
Clearances between the bearings and corresponding pins .......................===rereereeererre ne rer eee aee eee eee e rer e eee 64
CONNECT 58
Connecting rod alignment RP 59
Connecting rod with Bearings and pin …..…......….....…ceerreeeeseeeeee ee ere een seee eee ee eee are r eee serre ee eee eee nee e eee eee eee eer e ear aaa a anna 58
Connecting tod, Weight EPR 58
COOlING fAN ..….…..…............…..errrreeeeseeee en erere enr ree cree eee e eee eee eee eee eee ee eee rare serre ee eee e eee e eee eee eee ee are e eee e eee eee ee eee 33
Crankcase breather LDW 5O2 .................……ccerserecenerereeneareeeaeeer een aee een saee eee rence are eee rare eee rare e eee eee eee ce eee eee eee 44
Crankcase vacuum regulator valvE ……......…............…reereseeeeereeeree ne ree ce ne serre nee ee nee nana eee nes ee eee eee e res e eee eee ee eee eee eee 43
Crankshaft axial clearance ….…....….............…cerserecererereeneareeeaeeeer eee eee cena eee e eee eee ane r eee eee eee rare ee are e eee e eee rare eee eee 61
Crankshaft front and back oil seal riNGS .…….....…......….....…eerrereeee serre ee reerre ne sae rene ererr era eee ane ee eee e eee aa e eee ere e senc eee 62
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 5 -
= | Chapter index
Crankshaft timing pulley SP 36
Crankshaft, check journals and Crank EHRE RR EERRRERRREERRKRRERKRREEKRREERKREEERKRRERKRRERKERKERKRKAERRKRERRKRERKERKEERKREERKKEEEEEEG 63
Crankshaft, [01 oY Loz= 1a To] a IN 11 a =P 63
(OV Ta To TT gl aT=T= To B= TTS = 0 0 oP 57
Cylinder head tightening procedure LDW 1204-1204/T-1404 ........ooi irises eee eee eee eee aera eee enna 57
Cylinder head tightening procedure LDW 502-602-702-903-1003 ..... coors e eran renee a eeans 57
CYLINDER HEAD, eMOVal er eee eee eee etter eee eee teat eee eee AAA aa AAA ane aa ea RAA Cana Anne 48
Cylinder rOUGNNESS RP 0 59
O) [[- Po eee ee area eee ee eee ee serre eee e eee e eee eee e ere eee eee cernes eee ee000 59
CYLINDERS PERSP 59
Driving pulley .…...................eereeeseeeeeeeee een ree cena eee eee ee ee aa eee nee eee ee eee eee eee eee eee eee eee eee e eee eee eee eee eee eee eee 34
Dry type air filter 29
E.G.R. CiFCUÏt ………........…..csserreeeenaeseere eee ne serre eee ne reree nee ares een eee area e ee eee eee eee nee near eee eee area eee cena eee aes 30-31
ЕхПаиз! тат! ода EEE 32
A-| er ERRRREERRRRERKRRERKRRERRKRKERKRRRERKRRERRERKEERRREEARKEERARKARERARERARREEREREEERRKAEERKREERAREEERKKEEEKRAEERKREEKERKEEEKAREEKKKEEKKKEEEEG 34
Fuel rail 44
Fuel tank (optional) SPP 33
GOVErNOr SPrINGS ..…................rrerecereeree ee seeee een are rene sara eee eee eee eee eee eee eee eee ee eee ee eee eee eee eee eee eee area eee e rence eee 40
Governor springs for Gensets .….…............….....……ccerrrereeneereeeereeere eee rer ee ne serre ee ee nee e nee eee eee ee eee eee nee e aa e race eee cesse een eee 40
CE 56
Hydraulic pump driVE ee eee eee e eee eee tees settee ete e seas este esse esate essa COCA vere RO EUEEEUnaCE CEN FEEUEa 65
To [=Te1 ToT aI e181 a a] o IeToT {eH To ANP 44
Intake / Exhaust / Injection camshaft lobe height - LDW 903 .... coor eee eee 47
Intake manifold — RemMOLE Air filer ........ oe eee ar ere ne see rene rare res e eee ea rare eee eee eee serre eee cesser ee 30
Journal and connecting rod PINS diameterS .……….....….............…...reeeeeeeerreneeseee nas eee eee ar crea eee re eee ee eee ea eee e eee e eee ane n en eeenece000 63
Main bearings and connecting rod big ends diameters ….…....…..................…ereeerrereeneeseeeenrerrr eme raree an see eee ee eee e een een 64
Oil bath air cleaner ( ON rEQUESt ) …….................….....csrercrrreceerreree cena rerree cena ranren een ares een een e es ee rennes eee eee nas een eee ane e eee ee 29
Oil pan, removal PSN 52
Oil pump - disassembly …..….....…....…....…ccrerecsser carre ne ere ren ne nca nre ne rene aa e acer eee reset ease e eset e esate este essa e esas estas eesa ee ssn senna eenes 42
Oil pump - ReassemDly PSN 42
PISTON TT 52
Piston ClEAraNnCE 55
Piston coolant NOZZlE€S .….….....…......…...rereceeeeeeen serre een eer een eaee eee rare ee aa eee ae eee e eee rare e eee eee eee e rare eee eee rare e eee eee eee 61
Piston ring, Clearance between GrOOVES .…….............…......…reccceeeecereereee en eeere ere ree cena rer een een cena race nes ee eee rare ee eee een rene ane 54
Piston ring, mounting order een es eee e eee rence near eee eee eee eee eee e eee eee rare ee ere eee e eee 55
Piston rings - End GAPpS ….............…...…erccerrereeee serre ee ee ere ee ne ree eee eee eee eee ee ee nes ee eee eee ee ere eee ee eee eee eee eee eee eee rare e ere een eee e ee 54
Piston, assemDly.......................erreeeeereereceerere meer ee eee ee eee nee ee eee eee eee eee ee eee ee ee eee eee eee e area e eee eee eee eee eee ee eee eee eee eens 55
PiStON, o CO 53
Piston, disassembly and inspection ....................-......eeereíreeeeer reece e etree eee ee tee ee tree ata e ae eee erate een EUA: 53
1S 00 TR Y= Te | oF UP 54
Pre-combustion chamber .……...................…eerseeeeceeerrre ne rre cree serre near ere ne sa eee eee ee nee naar eee serre eee eee eee eee eee eee eee e eee 51
Pre-combustion chamber ring nut rEMOVAÏ …............…....……eccccrerrecereecee ne seer eee arre eee ree een rare ee aa recenser e etree eee e rea e eee e ees 51
Pre-combustion chamber, installation ….…..............….......resresrerr are ar enr a a nana n a aan ae aa ane ane aa aa aa aa aa eee aan ae a ea a ana annee 51
Pre-combustion Chamber, FEIMOVAL ..... coo RR RRERRRR RER RRRRRRRRRRRRRERERRRRRRRRRRRRRRRRRRRRERERERERRRRRRRERRRRRRRRERERERERERRRRARRRREEG 51
Pump/injector unit - DISASSEMDIY ......ooo ee eee eee eee eee tetra eee eee eee eat e nee nes 45
Pump/injector unit - Non-retUrn ValVE ….....….........…...ccrrrrrreece resserre creer ereer eee e a reer ee een as ere e asser eee enr e eee e nee nee 45
Rear and forward main bearing CAPS …….............….....…ceersereceneereee ne raeee en reere enr aee cena see eee ee eee are een eee eee rare ee eee een eee eee 60
RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING .…...........…….+erecceerreneeseee eee rer eee eee eee 28
RECOMMENDATIONS FOR OVERHAULS AND TUNING een e eens eran e eee e eee 28
CU) RERRRRERRREERKREERRRREEERRREERKREERERARERKRREEKRREERERAEERKARERKAREERKRERERRARERKREERAREEERKRKEEKRAEEKRREERRKEEERKKKEEKRKEEKRKEEEE 34
Ringfeder-type rings on LDW 1204-1204/T-1404 ... coor ieee eee eee eee eee eee erate eee aetna eerie aaa eeeeeees 35
Ringfeder-type rings on LDW 1204-1204/T-1404 - ASSEemDlY ………........…......rererercca resserre crane ssrre cree ne reer eee e a raa rence asser 35
Rocker arm assembly .….….............…...recceererereeeeeeeee enr eer ee ne rar cena serre eee eee e eee ee eee eee eee see e area eee are e eee eee eee ee eee e nee ce EUA: 45
Te qT a= TT oo Y= eee rene aa eee near eee rare ee serre ee rare rare eee seen ee eee e nee eee eee ee eee eee eee 42
Rocker arm cover gaSket ne areee ne reeee een ar eee an eee eee e eee rene aa eee ae seen e eee een serre eee eee area eee 43
Rocker arm pivot, dismounting and reMmOUNtING …....….................rreeceererree rer cena seee ee erer cena ee een eee e rare ee eee eee eee ere 46
Shoulder half riNGS …..….............…cerrerece creer eee eee ee nee ee eee nee eee eee eee ee ee eee eee ee serre ee eee e eee eee eee e eee eee rare ee eee e area eee 61
Shoulder half rings, oversized elements ……...….......….....…...rrerrereeeeecenserrre ne are rene eeere en reer e er eee are eee eee ee eee eee 62
Speed GOVEMNON ..........…..........…crrrcececeeree ee reere ee aare een eree eee eee ee eee eee eee eee eee eee eee eee eee eee eee eee eee ee eee eee eee eee eee eee 40
Speed governor - Limiting speed GOVEMNOF.....…..............…...…ccecesereecenereeceneseee een rer cena aee eee eee r een ae eee ae ee eee rare e een 41
Speed governor - ReassemDly .……....…............……receseeeeceeeereeenereee ane er eee aa ere nee eee e eee ere nee eee ee eee eee eee e eee eee rare e eee ae anna 41
Speed governor COMpONENtS …...................ccrerecserccreren sara carence nana ea sance nee a nana race seen e rene nana nee en eee nana nana cena n nanas 40
Stop pin rings, dismounting and reMmOUNtING ..……....................cerrececerereeee ne serre ere rer een aee eee eee e eee ee eee ea eee career cesse eee 52
EEE 65
ТПоМегтмипо рийеу..........ееееееннееенннннннннннннененненеенннеенененннныенненеыннннннеынннннеыенннннныыннныеенннеыннннныеноненныннненоннннноанненеееынноннное: 36
Timing belt / Timing pulley arrangement …..….…..….......….…......…rreecereresrreece ne ssere crea a rere ere nana rene eme s race eee area e nee essence see 36
Timing belt COVEr ............….......cerserecereereene serre ee ere rene aae eee eee eee naar eee eee ee eee eee eee eee eee eee eee serre eee ee serre eee ere ee ce e 35
-6- FOCS Workshop Manual cod. 1.5302.351 7° ed_ rev. 06
KOHLER Chapter index | =
Timing belt remOVal ee ERRRRRERKRRRKRRERRRRERKRRERKRRERMRREERKRERERKRRERMKRERKAREEERRKEERKARERAKEEERKARERKRREERKREEERKKEERKRKEEKKKEERKKEEEET 36
Vacuum pump and vacuum pump FLANGE .......oo eee eee eee 33
Valve / Rocker = Td (SF = = [oR 44
Valve guide Insertion …...........…..........…ereeerereeeeeeeee eee ree ce ne rere eee ee nee aee ee eee ee eee eee eee ee eee eee ee eee e eee e eee rare e rare eee ee 49
Valve guides and valve guide NOUSINGS …..................…...ceeececcereeeene serre ere eeere eee een ee ae eee eee a eee eee eee near eee rares 49
Valve recess and seat Sealing WIth o.oo. eee re rene e eee eee e eee e eee reer eee rare a eae aaa 50
Valve seats and housings - DImenSiONS eK RR RRKRRERRRRRERKRRERKRRERRERKERKRKEERRREERARKERERKREERRREERKREERKRKEERKKRERKKREEKEKEEG 50
Valve EEE 48
Valve stem sealing rings - ReassemblY eK ERRRRERRRRERKRRRKRRERRERREEKRREERRRKERRRRKERKRREEARKEERMKKEERKRREEKKREERKKEEEUKEG 48
Valve timing - Angles eK ERRRRERRREERKREERERREERRRREEKRREERRREEERRRAERKRRERKRRERRRRAEERRKEERKREKARKRERKARERKRREEKEREERKRKEERKKKERKKKEEKEKEEG 39
ECM io s-1e ER RRRRRRRRRRREEKRREERKREERKRREERKRRARKRREEKRREEERKARERKRRERARKERKERKEERRREERKKRERKERKERKRKERARKEEKAKKEERKRKEERKREERKREEEEEEG 38
Valve, Specifications .……..….....….....….erccrrercerere case r ce nrene rene nana nee nre ne ne nee seen e nee rene ea sen ee nana seen e rene ana n eee seen e rennes ane e ee nee 49
NC tiie eee eee eee eee eee eee eee eee eee ee eee ee eee ee eee ee eee eee eee ee eee e eee eee eee ee Serena 48
5 TURBOCHARGER …..................…..cecrcrecre cree see crane sera n eee eee e cena nana nana nee eee a ee eee een een eee crane een een een ane 66-67
LILO Ld = 10 I 0 1a {1 66
Turbocharger COMPONENtS …...................….errrereereereecen serre eme rer ee ae sere een ee nee ne aee eee eee e eee eee ee eee rares eeee area eee een een 66
Turbocharger pressure testing .…......…......…..........rreeeesereeenereeee ne serre eme rer cena aee eee eee e cena eee eee eee e eee eee e eee esse enr n ee c0 66
Turbocharger west gate adjustment - Regolazione corsa asta comando valvola " Waste gate " ess 67
6 LUBRIFIC ATION CIRCUIT ooo eee eee eee eee eee eee teeta eee eee ane eaanns 68-71
Internal oil filter and oil sump return PIPE «connie eee eee reese eee e sees eras esta east ee eee aesanas 69
LUBRIFICATION CIRCUIT ….........…..xccerrsrrrecce ne seere nee nareree nee na area e eee ner eee eee ere e eee een eee eee ee rer eee eee eee ee cena rase e eee essence 68
(O Mil| CI e ago [[- eee een eee e eee eee ee eee eee area ren eee eee eee eee eee ee eee eee eee eee eee area eee 70
Oil pressure CHhECK sea ce nee ne ran ana nae ace nee ne nana ea ea eee area area career eee ane n ace seance een ananas eee annee Sa races 70
Oil pressure regulating Valve …….................erecerereecenseeeee en eee cena ee eee eer eee eee area eee rare cesser eee eee ee serre eee ee asc eeneee 0 70
Oil PUMDP TT sa nana 69
Oil pump, clearance between rotors .......................e.eeieeriricircrrerer reee reee rarecenereererertvUceCEerrrEE ara CECRceeRO ERRE UaUCE ENEE RECUCIEN 69
7 COOLANT CIRCUIT EEE 72-73
COOLANT | {1 1 I SSSR 72
Coolant circulation pumMP, COMPONENTS Lo. eee eee eee eee e eee eee east ease eee e estas rena e essa 73
Radiator and compensation, check and seal tank CAP. .…….........…....…crcrecrrrrraneea carre na nara ca nae ne ere ann ae nana eee nee 73
BILLET Tes = Lo = YAR 73
8 FUEL SYSTEM ......................ceeccseccee core rene are ne rene ee rene ne nee n annee rene rene rene eee eee n crea rene eee cena crane nana ane sa nee a nca 74-83
Closing the oilnole RP 82
Fuel feeding / iNJECtION CIFCUIt..…........….......……cccsrsrereeece ss recre cena raneee cena en ee eee nes ee rence ae ras eee eee see e eee e eee cernes 74
Fuel filter detached from the tank (On request) .………........….........….crererrrreeceneserreerenanarenee nana sa ere eee a rare eee e nee esse 74
Fuel lift pump ..............eeeeeeeeeeveieerreeeereee erre reee re rca er eee rene area een ee ee eee ne eee ea ee eee ee eee ane eee eee ee nee eee e eee e eee a ea ee se eee eee seen 74
Fuel pump drive rod projection …..…..…...........…....….crrercsrereenser carre ne rara ea sen ce nre ne na nee seen e nana nana nan sean nana casa nee rene ana ane asan ce een 74
Injection advance control and regulation ……..….......….............eeeeereeeeseeeecenerre een saee eee eee ee naar rene serre eee eee e nes e serre rare nee 80
Injection advance for currently used pump/injector UNit ................-.eeee.2erereeer RR rrrererererrrrreEEErvErrrEERECNECENCOCOS 80
Injection advance references on timing belt protector ......................--......eree eee eee ee 81
Injection pump assembly/disassemblY ......... R RER RRRRRRRRERERRRERRRRRRRARKERKRRRARERRREREERRKRREERKREREEEERKREEERRERKEEEEREEKKEEG 76
Injection pumps delivery balANCING EN 83
Injector, nozzle projection ….....….............……..rrerecereereee serre een eera ee aa eee eee a eee eee eee e eee eee ee eee eee eee e eee eee eee eee eee ee eee eee nee 79
Injector, setting (Old type) .................….......rcrreecersrerren een rrere cran are rene ana ere eee raae ee eee ess eee eee se eee e near eee 79
Injector, spark arrester.....................__eee2ieeeeíirir reee rrrrrEreErrrErrrrrrErONErErECErrrEFE CC rrrEECCrrrrEFArrrrEE CC Err CEC rrrrEF ae rans 79
Instrument conneCtiON esse ERRRRRRRRRERKRREERRREERKRRERERRRARKRREERARKERRKRAEERKREEKEREEERKRERARRRERAKREEERRKEERRKRERKKRERKERKEEKKKEERKKEEERKKEET 83
Plunger barrel ring nut assembly/disassemblY ee. ieee eee eee eer 76
Plunger injection pump reassemMblY ee ERKRRRKRRRERRREERRRRRERKRRERRRREERKRRERKRKRERARKERKRRKEERKKEEKRKEERARKEEERKKEEKKREERKKEEEEEEG 76
Preliminary steps to pump/injector unit delivery balancing test …..…........…….......……rreeceseseereecenasrrerrre nan seer recense ere ec e 82
Pump/injector | USSR 75
Pump/injector unit se.no. 6590.285 CONtrol data. ..........ccoiiiiiiiiii eee a rare eee e a asen eee 77-78
Pump/injector Unit, COMpONENtS ersteren rede eee eee eee eee eee reat eee eats eset e ee eaaa ee eet ee sssaneaeennns 75
Pumping element RP 77
Pumping element (old-type injection PUMP) ….…….................…rrrreccrarerrereceerssreren een rene race asser areas eee nee anse ere 77
FOCS Workshop Manual_cod. 1.5302.351_7° ed_ rev. 06 - 7 -
= | Chapter index
Setting of injector according to current pump/injector Unit ers eee eee eer 79
Static injection advance regulation .……............….....…...ererrreesereeeeeeeee care eee ce ne see eee near een rer ee ee ee eee eee eee ea eee ee eee cesse eee 82
Static injection advance tUNING ….....…..............cerssereceerre ce eree een eeen een eee ee nes ee eee eee nee rer e ee ee eee are eee eee e eee eee eee 81
ТОС (Top Dead Center) references ……….…......…….….......……...crsrrrrreccnansrerree nan sreeren cena raaren een aan rene eme nas ee rence nanas eee cena annee nee 81
Test head B assembly …............….....….recrsereeceeeere ce erree nee eee eee eee rene eee eee e eee ee eee e eee eee e eee eee eee ee eee e serre career cerner 82
Tester and special coupling for injection advance control (Old-type injection pump) …….…..….…….....…….……rccrrrceeccsseeccuee 81
9 ELECTRIC SYSTEM oo eee near ere n ere n a nee eee ae nana een een caen crane een eee nana accent 84-93
Alternator battery charger curve 12V 20A ..…............ccrececenseeee ee arere ne saeee ne ere rene aa eee ee een een ae eee eee eee rare eee aan a eee ea e 89
Alternator battery charger curve 12V 3OA ..…............……crececeeseereeererere ne saeee ee ere rene aa eee ae ee nee see e eee serre eee eee area eee ea as 89
Alternator, AO TO 85
Alternator, Iskra 14V 33A - Performance [email protected] …....................acsresreseara aan ane na aan ne ane aan anna aan ane aa ea aan aa aa aa Aa ana aan 85
Alternator, Marelli type AA 125 R 14V 4DA eee eer eee senc eee eee serre ee eee e ere e area 87
Alternator, Marelli type AA 125 R 14V 45A - Performance CUrVE ….…......….......…..ccreccesrreeen serre ce erre een eaeee nee er ace rase 87
Coolant high temperature [am SENSO... eee eee eee eee eee na nana sance rene nana nas n ee nana san ere FUCUES 93
ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP couse eevee eee eee 84
Electric starting layout (12V) with flywheel alternator …….….......…….…....……eeceeeserreerenarrarer rene seer eee a eee eee eee eee 90
Electric starting layout (12V) with Iskra alternator 14V 338A oo. eee eee eee 86
Electric starting layout (12V) with Marelli type AA 125 R 14V 45A alternator …...….……......………eccessereereenanrsre races acces 88
Flywheel AlternatOr eK ERKRRERRRRRERKRRERKRRERKERKRERKRRERKRRERKERKEERKREEARREERAKKEERKARERKRREEKRKERERKREEERKAEERKREKAKKEERKRKEEKRKEERKKEEEEG 88
Oil pressure SWItCN .…....….........…ccserccrsene are ne area ce nee ee rae ae ana eee en ee ne eee eee ea eee area area casa eee nee nana ca seance annee ane esa encre ananas anne nan 93
Pre-heating glOW PlUG RP 92
Pre-heating glow plug control unit with coolant temperature SENSOr ...........i iii eee 92
STARTER MOTOR - Bosch DW 12V 1,1 KWi...............reeeeee2eeceeereerereeeeneneeerereerrererrrErrnnrerrreREENrrrreEECRNrCrCEN ECON Erre CEFCC CCA 91
Starter motor, Bosch 12V 1,6 KW LL. caca rca rare nan area a anna na ane ane aa ae aan aa ae aa aa aa aa ae AAA aan Aa ana ane ane aan ana Aa ARS 91
Starter motor, Bosch DW 12V 1,1 KW - Performance [email protected] .….....................ccrcsrearear ana ane area ae aan a aan ane aa ana ana a aan anna nana 91
Starter motor, Bosch DW 12V 1,6 KW - Performance [email protected] .…..…..…...............ccrcsrearear ana aan area ae ae na aan ane aa san ananas nan aan 92
Temperature sensor for control Unit.……….........…........csserrerseneererne ane re ereneanen ana sa naar eee ne nana sara er eee n ana case n eee rene an aan ee nana 93
Voltage regulator CONNECtIONS ….....…..................…+ereeceserecee serre een arer eme sae rene eee e naar ee ee sera eee eee eee eee ee eee e rare e eee e area ns 90
10 SA CE 94-97
E.G.R. calibration ve ERKRRRRRRRERRRRERKRRERKEREEERKREEKAREERRKREERKRREEKRREEMARKERERREEERRRERARREKERKEERKKRERKKRERREREERERKEERKKRERKKKEEEEHG 97
Injection pump flow limiter and standard engine torque gearing deViCE eK RR EER KR TIA 95
Pump injection delivery standard setting without dynamometric brake ..................—-...-.eeremieeeeeeereer RITA 94
Pump/injector unit delivery setting with braked engine ............cooo ieee 96
Pump/injector unit timing with speed GOVErNOF ……...............……ereccereserree cena renere cena nn arere nca nes eere eee a race cena es e nee nn seen 95
Required settings (as most commonly applies) ..........................1.e.er00reiieeererrr reee erre eran ererrrerenrrrrErErErrrErrEFEONECEECEEECT 96
Setting the idle maximum (standard) .....................-...=.1eeereeereeeeeere erre ere rrrrrrerenrrrrrrErECrrrrCE EEC AECrCECEFONECEFECEFECECCA 94
Setting the idle minimum (standard) ...................—.e....2reieeeerieeereeeee erre eser eee ce ne nene en ee ares ere e asser eee aa rare nee e seen eee 94
Setting the StOP .……..................…ereccesereeeeeere ce eaee eee eee e ee eee eee eee ee ee eee e eee eee eee eee rare ee eee eee eee e eee eee eee e eee e area aennnnn 95
SPEED SETTINGS …….....…..rrererreererereee ee nan rere race ner e eee e nee eee e ee ere eee ee ere e eee eee eee eee esse eee eee eee cena rase cena serre 94
11 STORAGE .........................cceccrererere rer crane rene rene rene rene rene rene rene rene ne ne rene rene rene een een caen eee nee nee ns ane e eee a eee a en a nee 98-99
ENGINE STORAGE (NOT INSTALLED) .………..........….....…rrsrrcrecenarereeeeenanererree cena serren cena raser eee asser eee cessera cena eee eee 98
PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT .….…........ccrcccccccceserrecce esse ce ecenneee 99
PROTECTIVE TREATMENT …............…eccorsrrrecrenaeeerere creme serre eee na eree nee aa ane e eee eee re rence seras eee e nee as eee eee ere e anse a sen eee 00 98
12 TORQUE SPECIFICATIONS AND USE OF SEALANT oe, 100-101
Table of tightening torques for standard screws (coarse thread) ve. EEE een nrare recenser eee een 101
Table of tightening torques for standard screws (fine thread) ……….….......……......creceersserrencenererrre een raner nec ans ee recense 101
Table of tightening torques for the Main COMPpONENtS …...................…..rceecererrrreneseeee en eeere ee arre ea a sa recenser area 100
13 SPECIAL TOOLS ...........................ecccsccrerecrerere cree crane rene eee rene rene rene rene rene rene rene rene sance en eee nee nee nee n caen een sen 102
-8- FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06
- The products manufactured by Lombardini Srl are warranted to be free from conformity defects for a period of 24 months from
the date of delivery to the first end user.
- For engines fitted to stationary equipment, working at constant load and at constant and/or slightly variable speed within the
setting limits, the warranty covers a period up to a limit of 2000 working hours, if the above mentioned period (24 months) is
not expired.
- If no hour-meter is fitted , 12 working hours per calendar day will be considered.
- For what concerns the parts subject to wear and deterioration (injection/feeding system, electrical system, cooling system,
sealing parts, non-metallic pipes, belts) warranty covers a maximum limit of 2000 working hours, if the above mentioned period
(24 months) is not expired.
- For correct maintenance and replacement of these parts, itis necessary to follow the instructions reported in the documentation
supplied with each engine.
- To ensure the engine warranty is valid, the engine installation, considering the product technical features, must be carried out
by qualified personnel only.
- The list of the Lombardini authorized dealers is reported in the “Service” booklet, supplied with each engine.
- Special applications involving considerable modifications to the cooling/lubricating system (for ex.: dry oil sump), filtering
system, turbo-charged models, will require special written warranty agreements.
- Within the above stated periods Lombardini Srl directly or through its authorized network will repair and/or replace free of
charge any own part or component that, upon examination by Lombardini or by an authorized Lombardini agent, is found to
be defective in conformity, workmanship or materials.
- Any other responsibility/obligation for different expenses, damages and direct/indirect losses deriving from the engine use or
from both the total or partial impossibility of use, is excluded.
- The repair or replacement of any component will not extend or renew the warranty period.
Lombardini warranty obligations here above described will be cancelled if:
- Lombardini engines are not correctly installed and as a consequence the correct functional parameters are not respected
and altered.
- Lombardini engines are not used according to the instructions reported in the “Use and Maintenance” booklet supplied with
each engine.
- Any seal affixed to the engine by Lombardini has been tampered with or removed.
- Spare parts used are not original Lombardini.
- Feeding and injection systems are damaged by unauthorized or poor quality fuel types.
- Electrical system failure is due to components, connected to this system, which are not supplied or installed by Lombardini.
- Engines have been disassembled, repaired or altered by any part other than an authorized Lombardini agent.
- Following expiration of the above stated warranty periods and working hours, Lombardini will have no further responsibility
for warranty and will consider its here above mentioned obligations for warranty complete.
- Any warranty request related to a non-conformity of the product must be addressed to the Lombardini Srl service agents.
1 - Use only genuine Lombardini repair parts.
Failure to use genuine Lombardini parts could result in sub-standard performance and low longevity.
2 - All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented in
Newton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and
pressure is presented in barometric units (bar).
For clarity, here are the definitions of a number of terms used recurrently in the manual.
- Cylinder number one: is the timing belt side piston .
- Rotation direction: anticlockwise «viewed from the flywheel side of the engine».
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06 - 9 -
1 | General remarks and safety information
- Important remarks and features of the text are highlighted Thisindicates thatitis necessary to take proper precautions
using symbols, which are explained below: to prevent any risk to the health and safety of individuals
and avoid financial damage.
T at g g , ifignored,
may seriously threaten the health and safety of individuals. This indicates particularly important technical information
that should not be ignored.
LOMBARDINI Engines are built to supply their performances in a safe and long-lasting way.
To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with
the safety recommendations listed below.
e The engine has been made according to a machine manufacturer's specifications and all actions required to meet the essential
safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.
All uses of the engine beyond those specifically established cannot therefore be considered as conforming to the use defined
by LOMBARDINI which thus declines all liability for any accidents deriving from such operations.
The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine
operation in particular, along with the relative routine maintenance work.
The user must read these instructions carefully and become familiar with the operations described.
Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the
vicinity of the machine.
* The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and
the deriving dangers.
This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the
latter case, must only be carried out by persons specifically trained by LOMBARDINI and who work in compliance with the
existing documentation.
Variations to the functional parameters of the engine, adjustments to the fuel flow rate and rotation speed, removal of seals,
demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall
relieve LOMBARDINI from all and every liability for deriving accidents or for failure to comply with the laws in merit.
On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ.
In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous
objects, also considering the movements made by the operator.
Pull-starting with a free cord (thus excluding self-winding starting only), is not permitted even in an emergency.
e Make sure that the machine is stable to prevent the risk of overturning.
e Become familiar with how to adjust the rotation speed and stop the engine.
Never start the engine in a closed place or where there is insufficient ventilation.
Combustion creates carbon monoxide, an odourless and highly poisonous gas.
Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.
e The engine must not operate in places containing inflammable materials, in explosive atmospheres, where there is dust that
can easily catch fire unles specific, adequate and clearly indicated precautions have been taken and have been certified for
the machine.
To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.
Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from
their operation.
Fuel is inflammable.
The tank must only be filled when the engine is off.
Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil.
Make sure that no soundproofing panels made of porous material are soaked in fuel or ail.
Make sure that the ground or floor on which the machine is standing has not soaked up any fuel or oil.
Fully tighten the tank plug each time after refuelling.
Do not fill the tank right to the top but leave an adequate space for the fuel to expand.
e Fuel vapour is highly toxic.
Only refuel outdoors or in a well ventilated place.
Do not smoke or use naked flames when refuelling.
* The engine must be started in compliance with the specific instructions in the operation manual of the engine and/or
machine itself.
Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).
Before starting, remove any tools that were used to service the engine and/or machine.
Make sure that all guards have been refitted.
- 10 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
General remarks and safety information 1
During operation, the surface of the engine can become dangerously hot.
Avoid touching the exhaust system in particular.
Before proceeding with any operation on the engine, stop it and allow it to cool.
Never carry out any operation whilst the engine is running.
The coolant fluid circuit is under pressure.
Never carry out any inspections until the engine has cooled and even in this case, only open the radiator plug or
expansion chamber with the utmost caution, wearing protective garments and goggles. If there is an electric fan, do not
approach the engine whilst it is still hot as the fan could also start operating when the engine is at a standstill.
Only clean the coolant system when the engine is at a standstill.
When cleaning the oil-cooled air filter, make sure that the old oil is disposed of in the correct way in order to safeguard
the environment.
The spongy filtering material in oil-cooled air filters must not be soaked in oil.
The reservoir of the separator pre-filter must not be filled with oil.
The oil must be drained whilst the engine is hot (oil T ~ 80°C).
Particular care is required to prevent burns.
Do not allow the oil to come into contact with the skin.
Pay attention to the temperature of the oil filter when the filter itself is replaced.
e Only check, top up and change the coolant fluid when the engine is off and cold.
Take care to prevent fluids containing nitrites from being mixed with others that do not contain these substances since
"Nitrosamine”, dangerous for the health, can form.
The coolant fluid is polluting and must therefore be disposed of in the correct way to safeguard the environment.
During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and
insulate the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from being
energized.
Only check belt tension when the engine is off.
e Only use the eyebolts installed by LOMBARDINI to move the engine.
These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should
be used.
The procedures contained in this manual have been tested and selected by the manufacturer's technical experts, and hence
are to be recognised as authorised operating methods.
A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of
operations.
All tools must be in good working condition so that engine components are not damaged and that operations are carried out
properly and safely.
lt is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.
Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this operation
to avoid the risk of amputation.
Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding
the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.
Do not use flammable liquids (petrol, diesel, etc.) to degrease or wash components. Use special products.
Use the oils and greases recommended by the manufacturer.
Do not mix different brands or combine oils with different characteristics.
Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.
Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.
Every organisation has a duty to implement procedures to In order to minimise the impact on the environment, the
identify, assess and monitor the influence of its own activities manufacturer now provides a number of indications to be
(products, services, etc.) on the environment. followed by all persons handling the engine, for any reason,
Procedures for identifying the extent of the impact on the during its expected lifetime.
environment must consider the following factors:
- Allpackaging components must be disposed of in accordance
- Liquid waste with the laws of the country in which disposal is taking place.
- Waste management - Keep the fuel and engine control systems and the exhaust
- Soil contamination pipes in efficient working order to limit environmental and
- Atmospheric emissions noise pollution.
- Use of raw materials and natural resources - When discontinuing use of the engine, select all components
- Regulations and directives regarding environmental impact according to their chemical characteristics and dispose of
them separately.
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 11 -
THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:
1) - The engine rpms suddenly increase and decrease;
2) - A sudden and unusual noise is heard;
3) - The colour of the exhaust fumes suddenly darkens;
4) - The oil pressure indicator light turns on while running.
TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS
The following table contains the possible causes of some failures which may occur during operation.
Always perform these simple checks before removing or replacing any part.
ELECTRIC
SYSTEM
MAINTENANCE
SETTINGS REPAIRS
Clogged fuel pipes
Clogged fuel filter
Air or water in the fuel circuit
Tank cap breather blocked
Faulty fuel pump
Lack of fuel
Glow plug fuse burned
Faulty glow plug control relay
Flat
Unclear or mistaken cable connection
Faulty starter switch
Fau motor
Faulty glow plugs
Clogged air filter
Prolonged operation at idle
Incomplete run-in
Overloaded engine
Excessive valve clearances
of valve clearances
broken or
Idle low
Worn out or stuck
Worn out nders
Worn out valve guides
Bad valve seal
Bearing shells of bearing cap - piston rod
rocker worn out
E.G.R. valve blocked
Governor not runni
inder head
au m
disengaged
Engine does not start
Engine starts but
No acceleration
Black smoke
Oil level increase
Excessive oil
consumption
from the exhaust
Engine overheats
Inadequate
performance
High noise level
Non-uniform speed
White smoke
Oil preassure too low
Oil and fuel dripping
- 12 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Technical information 2
No acceleration
Black smoke
Excessive oil
consumption
Inadequate
performance
High noise level
Non-uniform speed
White smoke
Oil level increase
Oil and fuel dripping
from the exhaust
Engine overheats
Engine does not start
Engine starts but
Oil preassure too low
High oil level
rty or pressure regu
|
r to the oil suction hose
Faulty manometer or re switch
LUBRICATION
Oil in sump drai blocked
Fau nozzles (Turbo ines on
in
m
| calibrated in
Worn or m element
Incorrect injection pump delivery setting
zZ
o
-
O
LU
=
=
Cracked or broken pre-combustion
Incorrect adjustment of the injection
ualisation advance
Insufficient refrigerant fluid
Defective fan, radiator, or radiator cap
Defective thermostatic valve
Loss of refrigerant fluid from the radiator,
Inside of radiator or coolant lines obstructed.
Defective or worn water pump
Alternator fan drive belt loose or torn
COOLING
CIRCUIT
Heat exchange surface of the radiator clogged
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 13 -
Technical information
Engine type
Engine serial number
Maximum operating speed
Number of the customer version
(form K)
-14 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Technical information
a ae
Е
Эт
| | |
о
ПЕНН
Se EEE e
us
Name plate for EPA rules applied on rocker-arm cap.
EE
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Technical information
Cylinders N° 2 2 3 4 4
Bore mm 72 72 72 72 72
Stroke mm 62 75 75 75 75
Displacements Cm*| 505 611 916 1222 1222
Compression rate 22,8:1 22,8:1 22,8:1 22,8:1 22,8:1
Rpm 3600 3600 3600 3600 3600
N 80/1269/CEE-ISO 1585-DIN 70020 9.8(13.4)11.8(16.0) 17.2(23.4) 24.2(33.2) 31.0(42.0}
Maximum power | NB ISO 3046 - 1 IFN - DIN 6270 9.1(12.4) 10.3(14.0)15.6(21.2) 22.0(30.0) 28.5(38.7)
NA ISO 3046 - 1 ICXN - DIN 6270 8.2(11.2) 9.2(12.5) 13.7(18.6) 19.9(27.0)25.8(35.0}
Maximum torque * Nm| 28.7 34.5 53,5 75.1 98
RPM| @ 2400 | @ 2200 | @ 2000 | @ 2200 | @ 2400
Maximum Torque Available @ N° 3 PTO 3600 Rpm Nm | 37/1800 | 37/1800 | 37/1800 | 37/1800 | 37/1800
Specific fuel consumption** g/KWh| 326 282 300 290 305
Oil consumption *** Kg/h | 0,007 0,007 0,012 0,017 0,019
Dry weight of engine Kg 60 65 85 96 101
Combustion air volume at 3600 Rpm 1./1'| 910 1640 1650 2200 | 2860.
Cooling air volume at 3600 Rpm m*/mm 36 43 63 88 109 ee
Axial load allowed on crankshaft (both directions) Kg.| 300 300 300 300 300
Instant operation (up to 1 min) of 35° 35° 35° 35° 35°
Max tilt Intermittent operation (up to 30 min) o| 25° 25° 25° 25° 25°
Permanent operation al + kk kk kk kk
Combustion sequence 1-3-2 1-3-4-2 | 1-3-4-2
* At NB power
** Referred to NB power LDW 502/602
Measured at NA power
Depends on application
. At 3600 Rpm
Measured at NB power
LDW 1204
LDW 903
LDW 1204/T
-16 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Technical information 2
Cylinders N 2 3 4
Bore mm 75 75 75
Stroke mm| 77.6 77.6 77.6
Displacements Cm*| 686 1028 1372
Compression rate 22,8:1 22,8:1 22,8:1
Rpm 3600 3600 3600
N 80/1269/CEE-ISO 1585-DIN 70020 12.5(17.0)19.5(26.5) 26.0(35.2)
Maximum power | NB ISO 3046 - 1 IFN - DIN 6270 11.7(16) | 18(24.5) |24.5(33.3)
NA ISO 3046 - 1 ICXN - DIN 6270 10.7(14.5)16.5(22.4) 22.4(30.5)
Maximum torque * Nm| 40.5 67.0 84.0
RPM | @ 2000 | @ 2000 | @ 2000
Maximum Torque Available @ N° 3 PTO 3600 Rpm Nm ([email protected]|[email protected] [[email protected]
Specific fuel consumption** g/KWh | 320 300 325
Oil consumption *** Kg/h | 0,009 0,013 0,019
Dry weight of engine Kg 66 87 98
Combustion air volume at 3600 Rpm 1./1'| 1240 1850 2470
Cooling air volume at 3600 Rpm m*/min 43 63 88
Axial load allowed on crankshaft (both directions) Kg. 300 300 300
Instant operation (up to 1 min) OL 35° 35° 35°
Max tilt Intermittent operation (up to 30 min) ol 25° 25° 25°
Permanent operation OL FREE FREE FREE
* At NB power
** Referred to NB power
*** Measured at NA power
**** Depends on application
. At 3600 Rpm
.. Measured at NB power
LDW 702
LDW 1404
LDW 1003
FOCS Workshop Manual cod. 1.5302.351_ 7° ed rev. 06 - 17 -
2 Technical information
1200 1600 2000 2400 2800 3200 3600
r.p.m.
cv
29
241
200
LDW 903
40 |
37
Kgm
5,5
} 4,5
g/CVh
LDW 502 LDW 602
cv Kgm Kgm
3,8
3 3,5
27 127 3,2
24 124 2,9
21 124 2,6
16+ 2,3
181
14+
161
12-1
14+
101
12-1
81+
10+
61
81
41- g/CVh g/CVh
; 340 6 220
1 320 [240 al
200
300 220
280 180
160
300 —-220
280
260
240 180
160
200
2000 2400 2800 3200 3600
r.p.m.
N (DIN 70020) Automotive rating, intermittent operation with variable speed and variable load.
NB (DIN 6270) Rating with no overload capability, continuous light duty operation with constant speed and variable load.
NA (DIN 6270) Continuous rating with overload capability, continuous heavy duty with constant speed and constant load.
C (NB) : Specific fuel consumption at NB power
Mt : Torque at N.
a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI.
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the
environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every
100 m di altitude and by 2% every 5°C above 25°C.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
Non-approval by Lombardini for any modifications releases the company from any damages incurred by the
engine.
- 18 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Technical information 2
LDW 1204 LDW 1204/T
cv Kgm Kgm
8 10
7 9
6 8
40+ 5 7
6
35-1
301
251
20-1
15-1
104 g/CVh g/CVh
220 220
51 200 200
180 180
160
1 1600 2000 2400 2800 3200 3600
r.p.m.
N (DIN 70020) Automotive rating, intermittent operation with variable speed and variable load.
NB (DIN 6270) Rating with no overload capability, continuous light duty operation with constant speed and variable load.
NA (DIN 6270) Continuous rating with overload capability, continuous heavy duty with constant speed and constant load.
C (NB) : Specific fuel consumption at NB power
Mt : Torque at N.
a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI.
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the
environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every
100 m di altitude and by 2% every 5°C above 25°C.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
Non-approval by Lombardini for any modifications releases the company from any damages incurred by the
engine.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 19 -
2 Technical information
LDW 702 LDW 1003
- 66
- 6.3
+ 56
5.1
E 8 8 8 &
- 45
10 e
3 256
330
9 310 f 200
8 290 Late
270
7 À 196
250
1600 2000 2400 2800 3200 3600 1600 2000 2400 2800 3200 3600
EDIT tpm.
LDW 1404
cv kgm
82
76
7.1
8.6
sé ud
el
a8 +
37 —
30 —
28 =
26 —
24 |
22 - g/0vh
250
O
230
18 -
210
18 -
190
1600 2000 2400 2800 3200 3600
N (DIN 70020) Automotive rating, intermittent operation with variable speed and variable load.
NB (DIN 6270) Rating with no overload capability, continuous light duty operation with constant speed and variable load.
NA (DIN 6270) Continuous rating with overload capability, continuous heavy duty with constant speed and constant load.
C (NB) : Specific fuel consumption at NB power
Mt : Torque at N.
a : Range of application for continuous operation. In case of application outside this range please contact LOMBARDINI.
The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the
environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every
100 m di altitude and by 2% every 5°C above 25°C.
Note: Consult LOMBARDINI for power, torque curves and specific consumptions at rates differing from those given above.
Non-approval by Lombardini for any modifications releases the company from any damages incurred by the
engine.
- 20 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Technical information
351.5
369.5
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 21 -
2 Technical information
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- 22 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Technical information
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513
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534.5
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FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
may lead to technical damage to the machine and/or system.
Engine oil replacement. Oil filter replacement.
FREQUENCY x HOURS
OPERATION DESCRIPTION
ENGINE OIL LEVEL
COOLANT LEVEL
AIR FILTER (DRY-TYPE)
RADIATOR EXCHANGE SURFACE
VALVE CLEARANCE ADJUSTMENT
FAN / ALTERNATOR
CHECK BELT STRETCH
COOLING LIQUID HOSES
SETTING AND INJECTORS CLEANING
FUEL PIPES
RUBBER INTAKE HOSE (AIR FILTER AND
INTAKE MANIFOLD)
INTERIOR RADIATOR CLEANING
ALTERNATOR AND
STARTING MOTOR
ENGINE OIL *) 7
OIL FILTER (*) UU
FUEL FILTER (*)
ALTERNATOR BELT (**)
COOLANT (**)
FILTER ELEMENT PANEL AIR FILTER (***)
FUEL PIPES (*)
REPLACEMENT| COOLING LIQUID HOSES (**)
RUBBER INTAKE HOSE (AIR FILTER AND| (**)
INTAKE MANIFOLD) (**)
TIMING BELT (*) EVERY 4000 HOURS
kkk
DRY AR CLEANER EXTERNAL (7) AFTER 6 CHECKS WITH CLEANING
CARTRIDGE
DRY AIR CLEANER INTERNAL | (***
(7 AFTER 3 CHECKS WITH CLEANING
CARTRIDGE
OVERHAUL | PARTIAL
TOTAL
STANDARD OIL SUMP (*) - In case of low use: every year.
(**) - In case of low use: every 2 years.
777 (***) - The period of time that must elapse before cleaning or replacing the filter element depends
797 ENHANCED OIL SUMP on the environment in which the engine operates. The air filter must be cleaned and
’ replaced more frequently In very dusty conditions.
(°) - Once removed, the timing belt should be replaced even if its scheduled motion period is
not over.
- 24 - FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Maintenance - Recommended oil type - Refilling 3
SAE Classification
In the SAE classification, oils differ on the basis of their
viscosity, and no other qualitative characteristic is taken
into account.
The first number refers to the viscosity when the engine is
cold (symbol W = winter), while the second considers
viscosity with the engine at régime.
The criteria for choosing must consider, during winter, the
lowest outside temperature to which the engine will be
subject and the highest functioning temperature during
summer.
Single-degree oils are normally used when the running
temperature varies scarcely.
Multi-degree oil is less sensitive to temperature
changes.
SAE 5W-30 ***
SAE 5W-40 ***
SAE 0W-30 ***
*Mineral base
SAE- Grade ** Semi-synthetic base
*** Synthetic base
International specifications
They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing
and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.
A.P.l : (American Petroleum Institute )
MIL : Engine oil U.S. military specifications released for logistic reasons
ACEA : European Automobile Manufacturers Association
Tables shown on this page are of useful reference when buying a kind of oil.
Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands
and choosing the kind with the right characteristics.
Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.
An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.
ACEA Regualtions - ACEA Sequences
PETROL HEAVY DUTY DIESEL ENGINES
Low-viscosity, for frictions reduction
tandard
igh performances
eavy conditions (Euro 1 - Euro 2 engines )
eavy conditions (Euro 1 - Euro 2 - Euro 3 engines )
¡High performances in heavy conditions (Euro 1 - Euro 2 -
LIGHT DUTY DIESEL ENGINES
Low-viscosity, for frictions reduction Euro 3 engines )
tandard
igh performances (indirect injection)
igh quality (direct injection)
API / MIL Sequences
PETROL
E
DIESEL
|
SETE
EEK
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 25 -
3 | Maintenance - Recommended oil type - Refilling
API SJ/CF
ACEA A3-96 B3-96
MIL - L-46152 D/E
AGIP SINT 2000 specifications
5W40
In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the
military specification MIL-L-2104 C/46152 D.
| LDW 602 | LDW 903
LDW 502 | | vy 702 | LOW 1003 | LDW 1204 | LDW 1404 | LDW 1204/T
OIL VOLUME AT MAX Sheet STD oil sump. | 1,5 1,6 2,4 3,2 3,2 4,3
LEVEL ENHANCED aluminium oil Litres
(OIL FILTER INCLUDED) |sump. 2,5 2,5 3,8 5,2 5,2 -
Sheet STD oil |
OIL VOLUME AT MAX Shee ой sump 1.4 1,5 2.3 3,0 3,0 4.1
LEVEL ENHANCED aluminium oil| Litres
(WITHOUT OIL FILTER) |sump. 2,4 2,4 3,7 5,0 5,1 -
* With dynamic balancer
If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the
standard sump and every 150 hours for the enhanced sump.
- The engine may be damaged if operated with insufficient lube oil. It is also dangerous to supply too much lube oil
to the engine because a sudden increase in engine rpm could be caused by its combustion.
- Use proper lube oil preserve your engine. Good quality or poor quality of the lubricating oil has an affect on engine
performance and life.
- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking,
and accelerated wear of the cylinder liner, bearing and other moving components increases significantly.
- Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.
The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.
- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.
- Do not disperse the oil in the ambient, as it has a high pollution power.
- 26 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Maintenance - Recommended oil type - Refilling 3
- The fluid coolant circuit is pressurized. Inspections must only be made when the engine has cooled and even in
this case, the radiator or expansion chamber plug must be unscrewed with the utmost caution.
- If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the
engine is at a standstill.
- Coolant fluid is polluting, it must therefore be disposed of in the correct way. Do not litter.
The anti-freeze protection liquid (AGIP ANTIFREEZE SPEZIAL) must be used mixed with water, preferably decalcified. The
freezing point of the cooling mixture depends on the product concentration in water, it is therefore recommended to use a 50%
diluted mixture which guarantees a certain degree of optimal protection. As well as lowering the freezing point, the permanent
liquid also raises the boiling point.
Coolant refueling
LDW LDW LDW LDW LDW
502 602-702 903-1003 1204-1404 1204/T
0,75 0,90 1,30 1,75 1,90
For information concerning the capacity of Lombardini radiators, please contact Lombardini directly.
The total volume for refilling the cooling liquid varies according to the type of engine and radiator.
To achieve optimum performance of the engine, use good quality fuel with certain characteristics:
Cetane number (minimum 51):indicates the ignition quality. A fuel with a low cetane number may cause problems when starting
from cold and have a negative effect on combustion.
Viscosity (2.0/4.5 centistokes at 40°C): this is the resistance to flow and performance may decline if not within the limits.
Density (0.835/0.855 Kg/litre): alow density reduces the power of the engine, and density that is too high increases performance
and opacity of the exhaust
Distillation (85% at 350°): this is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light
hydrocarbons may have a negative effect on combustion.
Sulphur (maximum 0.05% of the weight): high sulphur content may cause engine wear. In those countries where diesel has a
high sulphur content, it is advisable to lubricate the engine with a high alkaline oil or
alternatively to replace the lubricating oil recommended by the manufacturer more
frequently.
Fuel with low sulphur content API CF4 - CG4
Fuel with high sulphur content API CF - CD -CE
The countries in which diesel normally has a low sulphur content are: Europe, North America and Australia.
FUELS FOR LOW TEMPERATURES
It is possible to run the engine at temperatures below 0°C using special winter fuels. These fuels reduce the formation of paraffin
in diesel at low temperatures. If paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.
Fuel can be: - Summer up to 0°C
- Winter up to -10°C
- Alpine up to -20°C
- Arctic up to -30°C
For all fuel types, the cetane number cannot be lower than 51.
AVIATION KEROSENE AND RME FUELS (BIOFUELS)
The only Aviatin fuels that may be used in this engine are: JP5, JP4, JP8 and JET-A if 5% oil is added.
For more information on Aviation fuels and Biofuels (RME, RSME) please contact the Lombardini applications department.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 27 -
To locate specific topics, the reader should refer to the index.
— Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions,
repair and operating instructions.
— Always use original LOMBARDINI spare parts for proper repair operations.
— The operator must wash, clean and dry components and assemblies before installing them.
— The operator must make sure that the contact surfaces are infact, lubricate the coupling parts and protect those that are
prone to oxidation.
— Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out
operations correctly and safely.
— For safety and convenience, you are advised to place the engine on a special rotating stand for engine overhauls.
— Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the
operator and any persons involved.
— In order to fix assemblies and/or components securely, the operator must tighten the fastening parts in a criss-cross or
alternating pattern.
— Assemblies and/or components with a specific tightening torque must initially be fastened at a level lower than the assigned
value, and then subsequently tightened to the final torque.
To locate specific topics, the reader should refer to the index.
— Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out
operations correctly and safely.
— The operator must comply with the specific measures described in order to avoid errors that might cause damage to the
engine.
— Before carrying out any operation, clean the assemblies and/or components thoroughly and eliminate any deposits or
residual material.
— Wash the components with special detergent and do not use steam or hot water.
— Do not use flammable products (petrol, diesel, etc.) to degrease or wash components. Use special products.
— Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them.
— Apply a layer of lubricant over all surfaces to protect them against oxidation.
— Check all components for intactness, wear and tear, seizure, cracks and/or faults to be sure that the engine is in good
working condition.
— Some mechanical parts must be replaced en bloc, together with their coupled parts (e.g. valve guide/valve etc.) as specified
in the spare parts catalogue.
During repair operations, when using compressed air, wear eye protection.
- 28 - FOCS Workshop Manual cod. 1.5302.351_ 7° ed_ rev. 06
Disassembly / Reassembly 4
Dry type air filter
Never clean the filtering element with highly flammable
solvents Danger of explosion!
inside the cartridge at a pressure no greater than 5 atm or if
necessary knock the front of the cartridge repeatedly against a
flat surface.
Components: 1 Cover
2 Filter element
3 Support
Air filter specifications:
Filtration level =13+14 pm.
Filtration area = 4470 cm? per LDW 502, 602, 903, 702, 1003
Filtration area = 7150 cm? per LDW 1204,1404
< See page 24 for periodic maintenance details.
Air restriction switch
Components:
1 Reset buttione
2 .25" Tab connection
Note: The indicator is calibrated at 600+650 mm of water column
for LDW 502, 602, 702, 903, 1003, 1204, 1404; and 370+420
mm of water column for LDW 1204/T.
Oil bath air cleaner ( on request)
y.
Replace the sealing rings if hardening or damage is noted
1 Upper Housing 6 Oil level reference mark
2 Diaphragm Seat 7 Reservoir bowl
3 Diaphragm 8 Outer seal ring
4 Polyurethane upper element 9 Inner seal ring
5 Metal wool lower eleme
Note: Carefully clean the reservoir bowl and both elements with
clean diesel fuel. Blow the lower element dry with
compressed air. Dry the upper element by squeezing out
excess diesel fuel, then drying with suitable cloths.
Fill the reservoir with clean engine oil to the reference mark.
< See page 24 for periodic maintenance and replacement details.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 29 -
4 Disassembly / Reassembly
Air filter support
The support for air filter 1 incorporates the intake manifold and the
accelerator control box.
Remove all bolts that secure the air filter support 1 to the cylinder
head. Carefully pull the air filter support from the cylinder head.
Using suitable pliers, release the governor spring 2 from the air filter
support assembly.
Replace the gasket 3.
Intake manifold — Remote air filter
- Unscrew the the fastening screws (1) that fix the intake duct to
the intake manifold unit.
- Unscrew the two fastening screws (2) of the intake manifold from
the engine crankcase.
- Lift the intake manifold and disengage the hook of the min/max
cylinder from the same manifold (fig. 212).
a Components:
y me 1. Exhaust manifold
“a 2. E.G.R. Pipe
SEN 3. E.G.R. Valve
> 11 4. Vacuum pump
5. Three way union
6. Vacuum pump pipe
7. Thermovalve — vacuum pump
connection pipe
. Vacuum valve — thermovalve
connection pipe
9. Vacuum valve - E.G.R. connection
pipe
10. Thermovalve
11. Vacuum valve
12. ON-OFF sensor control cam
13. Intake duct
Qo
- 30 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Disassembly / Reassembly 4
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Pa Roig
E.G.R. Circuit
Operation
The main function of the E.G.R. (Exhaust Gas Recirculation)
system is the reduction in emission of NOx (nitrogen oxides), gases
harmful to people and the environment, via lowering the
combustion temperature.
The system takes a certain quantity of exhaust gas from the
exhaust manifold 1 (fig. 8) via the E.G.R. pipe (2) to the E.G.R.
valve 3.
This valve is opened by the vacuum (created in pipes 6, 7, 8 and 9
by vacuum pump 4; fig. 8) only when:
a) thermovalve 10 placed in contact with the engine refrigerant
fluid reaches a temperature of 40 °C;
b) the on-off sensor control cam 12 opens the vacuum valve 11 at
a determined accelerator position.
Once the E.G.R. valve is opened, the exhaust gas enters the intake
manifold 13 via the intake flange.
The same logic controls the closure of the E.G.R. valve.
Disassembly:
- Disengage the control rod catch (1) with a screwdriver from the
accelerator control rod (2) (fig. 9).
- Disconnect the accelerator control rod (2) from the accelerator
control lever (3) (fig. 9).
Disconnect the thermovalve — vacuum pump connection pipes
(7, fig. 8) and vacuum valve — thermovalve connection pipe (8,
fig. 8) from the thermovalve.
| - Unscrew the two fastening screws (5) that fix the E.G.R. pipe (6)
to the E.G.R. valve (4) (figures 10, 11 and 12).
- Remove the intake manifold. See "Intake manifold — Remote air
filter" on page 30 (Figure 7).
- Unscrew the fastening screw of the E.G.R. pipe support bracket
(9 fig. 10) from the engine crankcase and disengage the E.G.R.
pipe from the exhaust manifold.
Reassembly:
| When reassembling pay attention to the repositioning of the
gaskets and to the precise connection of the pipes (6, 7, 8, 9, fig.
8).
| These pipes should be carefully fitted on the appropriate
connections.
I O Tighten the screws to specified torque, see "Table of tightening
torques for the main components” on page 100.
< For the calibration of the E.G.R. system see "E.G.R. calibration"
on page 97.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 31 -
4 Disassembly / Reassembly
Vacuum pump and vacuum pump flange
Unscrew the three fastening screws 1 that fix the vacuum pump to
the flange and remove the vacuum pump.
| Unscrew the fastening screws that fix the flange to the engine
| crankcase and remove it.
Components:
. Vacuum pump
. Clic clamp 86-50
. Vacuum pump flange
. Vacuum pump gasket-
. Vacuum pump flange gasket
. Three-way union for vacuum pump
. Vacuum pump pipe
. Screw
. Screw
© O0 N ©) сл RONA
O
When reassembling, tighten the screws (8) that fix the flange to
the cylinder head to the specified torque of 10 Nm, and the screws
(9) that fix the vacuum pump to the flange at the specified torque
of 15 Nm.
Exhaust maniflod
scalds and burns.
When you dismount the exhaust manifold check that the inside is
properly clean and free from cracks or breaks.
Replace gaskets every time you remove the manifold.
O Tighten nuts at 25 Nm.
Exhaust manifold - engines with EGR
Remove the E.G.R. pipe (1).
Unscrew the locking nuts (2) and remove the exhaust manifold and
Note: When reassembling the exhaust manifold, check that the
inside is properly clean and free from cracks or breaks.
Note: Replace the gasket each time the manifold is reassembled.
O Tighten the nuts at the prescribed torque of 25 Nm.
- 32 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
Cooling fan
Carry out the cooling fan disassembly, only after isolating the
positive battery cable to prevent accidental short-circuiting
and, consequently, the activation of the starter motor.
Carefully clean and check all blades. Replace the fan even if there is
only a single damaged blade.
< See pages 16+17 for cooling air flow volume.
Alternator/Cooling fan belt drive
Check the belt tension only with the engine off.
Tension adjustment.
Loosen screws 1 and 2.
Adjust the belt tension so that a 100N force at the midpoint of the
belt center (as shown) results in a 10-15mm deflection.
< See page 24 for periodic maintenance details.
Fuel tank (optional)
To avoid explosions or fire outbreaks, do not smoke or use
naked flames during the operations.
Fuel vapours are highly toxic. Only carry out the operations
outdoors or in a well ventilated place. Keep your face well away
from the plug to prevent harmful vapours from being inhaled.
Dispose of fuel in the correct way and do not litter as it is highly
polluting.
After disconnecting the fuel pipes unscrew the anchoring brackets
screws and remove the fuel tank.
Completely empty the tank and check that no impurities are found
inside.
Check that cap breather hole is not clogged.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 33 -
4 Disassembly / Reassembly
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Flywheel
During dismounting be particularly careful not to let the
flywheel fall, as this can be very dangerous for the operator.
Use protective goggles while removing the starter ring gear.
Unscrew the screws that fasten it to the crankshaft.
In order to replace the ring gear, it is necessary to disassemble the
flywheel.
Cut the ring gear in several places using a chisel and remove it.
Heat the new ring gear uniformly and keep it at a temperature of
300°C for 15+20 minutes.
Insert the ring gear into its seat and place it carefully on the rim of the
flywheel.
eave to the ring gear to cool gently before reassembling the flywheel.
O When refitting tighten the screws at 80 Nm.
Return pulley
Remove the center bolt 1 and slide the pulley from the engine.
Components:
1 Bolt 6 Bearing
2 Washer 7 Spacer
3 Spacer 8 Bearing
4 Pulley 9 Snap Ring
5 Snap Ring
Note: On remounting thoroughly clean out the threads of screw 1
and tighten at 25 Nm.
Driving pulley
To loosen or screw in screw 1 at the set torque you must
always stop the crankshaft and not other parts of the engine.
Locking the crankshaft: remove the engine starter and installing the
fixture tool 1460-051.
Remove the pulley, after having unscrewed central screw 1 and
proceed with the four lateral screws.
The central bolt 1 is left-handed.
O When reassembling, apply some Moly-slip antiseizure compound
on the screw thread and tighten at 360 Nm.
Note: When pulley reference mark (A) aligns with the timing cover
reference mark (B), the flywheel side piston is at TDC.
- 34 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
NA AAA NTE TUE
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Ringfeder-type rings on LDW 1204-1204/T-1404
It is possible to draw % of the power from the second drive of LDW
1204-1204/1-1404 engines.
If you want to draw the entire power it is necessary to mount the
Ringfeder rings on the crankshaft handie.
Components:
1 Puleggia appropriata 6 Ringfeder external ring
2 Screw M6 7 Spacer flange
3 Screw M16 x 1,5 8 Shoulder plate
4 Ringfeder internal ring 9 Crankshaft
5 Screw M8
Ringfeder-type rings on LDW 1204-1204/T-1404 - Assembly
Refer to figures 25 and 26.
Clean and oil the parts involved in the mounting with engine oil.
Insert into pulley 1, the internal ring 4 and the external ring 6, then
flange 7 by tightening it temporarily with its screws.
Before assembling the pulley 1 in the crankshaft taper, insert
shoulder ring 8.
Lock the crankshaft using tool 7107-1460-051.
O Tighten the screws 2 at a torque of 10 Nm.
O Tighten the screws 3 at a torque of 360 Nm.
O Tighten the screws 5 uniformly in criss-cross pattern in three
distinct phases:
1° phase = 15 Nm
2° phase = 35 Nm
3° phase = torque check.
Timing belt cover
Loosen the five screws and remove the cover.
O When rifitting tighten the screws at a torque of 10 Nm.
Check the peripheral rubber sealing gasket and the two dust-
protection rings of the two pulleys, if mounted.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 35 -
Disassembly / Reassembly
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Timing belt / Timing pulley arrangement
Components:
1 Camshaft pulley
2 Timing belt
3 Crankshaft pulley
4 Coolant pump pulley
5 Belt tensioner pulley
Timing belt removal
prescribed operation time has not expired yet.
Always check that the positive pole of the battery is insulated.
Remove the belt tensioner 1.
Remove the timing belt off the timing pulley.
< For assembly see fig. 36.
Tightening pulley
Components:
1 Nut
2 Washer
3 Pulley
4 Bearing
5 Shaft/Support
6 Mounting plate
7 Tensioning lever
Crankshaft timing pulley
Al rimontaggio fare attenzione che la chiavetta rimanga inserita
nella propria sede.
Note: Reference mark 1 on the crankshaft timing pulley and
reference mark 2 on the oil pump housing are timing marks.
When aligned, No. 1 piston (flywheel side) is at TDC.
- 36 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
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Camshaft timing pulley - Disassembly/Assembly
-| Unscrew screw 1 and remove the pulley. No extractor is needed.
O When refitting tighten the screw at a torque of 80 Nm.
Note: Assess any wear caused by the lip of the seal ring on the
pulley tang.
Camshaft timing pulley - Reference marks
1 Timing reference mark on cylinder head.
2 Camshaft pulley timing mark, for LDW 502 engines only
3 Camshaft pulley timing mark, for LDW 602, 702, 903, 1003, 1204,
1204/T and 1404 engines.
Camshaft timing - Belt Reassembly
Remove e distributor
wrapping only when mounting it.
Make the connections for toothed belt fig. 33 and that of pulley fig.
34 fit together.
Insert the belt as in figure 35 taking account of the direction of the
arrows A impressed on it (direction of rotation).
Tighten the nut 1 by hand until the belt tightener rests on surface of
the crankcase.
Start by mounting the camshaft pulley belt, then mount crankshaft’s
pulley.
Do not mount driven belts.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 -37 -
Disassembly / Reassembly
Camshaft timing - Belt tightening tool
Position belt preload tool 7107-1460-049 1 over the timing belt idler
adjustment ear 2.
See "Camshaft timing - Belt Tightening and Fastening”.
Camshaft timing - Belt Tightening and Fastening
Insert the torque wrench in the suitable tool so that the A axis of
the key fig. 39 is at 90° to the B axis of the tool in fig. 38.
Tighten in clockwise direction at 20 Nm.
O Maintaining the belt tension, tighten nut 3 with another torque
wrench at 40 Nm, after having remounted the drive pulley.
Rotate the crankshaft a few times and check that the tension is as
described above.
The check must be carried out with the appropriate Nippon Denso
tension measuring instrument (halfway along the longest section of
the belt), the value for a cold engine must be 15+2Kg.
Valve timing check
A = Intake valve
B = Exhaust valve
Rotate the engine in the normal direction of rotation until the No. 1
piston (flywheel side) approaches TDC- compression stroke
Check the balance of intake and exhaust valves A and B placing the
two micrometers testers on the valve collars.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
Valve timing - Angles
The angle values are determined by turning the driving shaft
clockwise.
iston at top dead centre
S
| iston at bottom dead centre
UU
Ol = Intake valve open
B = Intake valve closed
ï = Exhaust valve open
= Exhaust valve closed
Timing angles for operating purposes
(valve clearance = 0.25 mm)
Ol = 16° before S
B = 36° after |
L = 36° before |
= 16° after S
Timing angles for checking puposes
(valve clearance = 2 mm)
o = 21° after S
B = closes in |
L = 2° after |
= 20° before S
Timing angles for operating purposes - LDW 1204/T
(valve clearance = 0.25 mm)
Ol = 10° before S
B = 42° after |
L = 56° before |
= 16° after S
Timing angles for checking puposes - LDW 1204/T
(valve clearance = 2 mm)
À = 31° after S
B = 1° after |
ï = 11° before |
= 29° before S
FOCS Workshop Manual cod. 1.5302.351 7° ed_ rev. 06 - 39 -
4 Disassembly / Reassembly
SPEED GOVERNOR
The weight-type mechanical governor, is driven directly by the
camshaft and is housed with the cylinder head.
Components:
1 Thrust washer
2 Spool
3 Flyweight assembly
Note: In engines with the minimum/maximum (see fig. 49) the
weights are lightened by 25%.
Speed governor components
1 Oil seal
2 Screw
3 Support
4 O-Ring
5 Bearing
6 Retainer
7 Screw
8 Flyweight assembly
9 Spool
10 Thrust washer
Governor springs
Unscrew the pin that attaches it to the cylinder head.
To remove it as shown in the figure it is necessary to dismount the
camshaft. It could also be removed from the accelerator box side by
unscrewing the torque gearing device.
Before reassembling it, check value A (45 to 46 mm) and the
parallelism of the two levels B that must not exceed 0.05 mm.
Note: There are 5 different types of regulator springs C. These
change according to the engine adjustment: standard spring
for 3,600 rpm, for 3,000 rpm, for 2,400 to 2,600 rpm, for
1,800 rpm and for 1,500 rpm.
Governor springs for Gensets
In the section view of the leverages the 4 ball bearings A are
highlighted.
They are mounted on engines for generator sets adjusted at
1,500+1,800 rpm and on other particular applications on request.
- 40 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
7
1 2 3 4 5 6
VAL A
ió
[a
Speed governor - Limiting speed governor
With applications for the automotive sector the regulator spring C
fig. 45 is replaced by a device (plunger barrel) that only enables a
constant speed at the minimum and maximum rpm rating.
Components:
1 Nut
2 Idle speed spring
3 Max. speed spring
4 Case
5 Register
6 Spring ring
7 Actuation rod
Note: There are six maximum springs in a different colours, to
distinguish them from the six respective adjustments.
Red color for... 3000 giri/1'
No color .................eeee——. 3200 giri/1'
Black ...............emeeeeeeeereeeeeees 3600 giri/1'
Orange ee 3750 giri/1'
N CE 4200 giri/1'
GreeN erster 4300 giri/1'.
=1£0)'/0 E 4500 gliri/1'
Speed governor - Reassembly
While reassembling, check the integrity
and check that they operate correctly.
of the components
| Bad operation of the speed governor can cause serious
damage to the engine and to people being near to it.
| Remount in reverse order to Fig. 44.
When inserting the bearing in the camshaft, do it so that the four
blocks enter opened, so that they can receive the hose and close
over it.
Check the integrity of the sealing rings of the cover.
O Tighten the three screws at a torque of 10 Nm.
Note: With the speed governor mounted the camshaft axial
clearance should be zero.
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 41 -
4 Disassembly / Reassembly
Oil pump - disassembly
The FOCS oil pump is supplied as an assembly. Lombardini
therefore recommends that the oil pump be handled as an assembly
from a service standpoint
Lombardini does not recommend that the oil pump be disassembled,
then reassembled for purposes of installation on the engine except
during emergency situations.
Rotate the crankshaft until the crankshaft timing pulley keyway is
vertical as shown. Remove the oil pump assembly retaining bolts.
When the crankshaft timing pulley keyway is vertical, the oil pump
drive keyway (A) will be at 3:00 o'clock allowing removal of the oil
pump assembly via relief (B).
Oil pump - Reassembly
The pump rotors should be coupled on the same side, see
references 2 and 3.
Replace the O-ring 1.
O Tighten the fastening screws to the crankcase at 25 Nm and those
of the plate at 10 Nm.
< See page 69 for technical details.
Rocker arm cover
The engine control components are all on the cylinder head.
The cover contains part of the lubrication duct of the camshaft and
of the rocker arms, as well as part of the engine vent system.
Components:
1 Oil preassure switch
2 Camshaft lubrification port
3 Rocker arm lubrification port
4 Oil exhaust hose from sump vent system
5 Air valve with oil decanting wire gauze
Note: During remounting be careful with oil exhaust hose 4 that
needs to be properly inserted into its housing on the cylinder
head.
- 42 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
Rocker arm cover gasket
The rocker arm cover gasket A ensures the seal of the lubrication
circuit for the camshaft and rocker arm shaft.
Always replace it and mount it with especial care above all in zones
1 and 2 where, for greater safety, it is advisable to apply a few
drops of silicon sealant.
O Tighten the rocker arm cover screws at a torque of 9 Nm.
Crankcase vacuum regulator valve
Components:
1 Gland Nut
2 Bushing
3 Body
4 Diaphragm
5 Cap / Cover
6 Clip / Lock
7 O-Ring
8 Washer
9 O-Ring
10 Valve
11 Spring
12 Tube
13 Hose
The vacuum relief valve is an engine safety device.
| Its function is that of limiting the vacuum whenever it tends to
_| increase.
“| Without this, should the air filter be clogged, the oil contained in the
carter may be sucked back into intake manifold causing the
condition for engine runaway.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06 - 43 -
4 Disassembly / Reassembly
Crankcase breather LDW 502
For LDW 602-702-903-1003-1204-1204/T-1404 engines, the exhaust
gases exit from the cylinder head cover, see Fig. 53, 54.
In the LDW 502 engine the exhaust gases exit directly from the
crankcase via cover 1.
Remove the cover, check the integrity of the air valve and oil
decanting wire gauze.
Valve / Rocker arm clearance
Bring each cylinder piston to top dead center on the compression
stroke and set clearance A at 0,20 mm for both the intake and
exhaust valves.
For greater convenience, clearance check B is accepted. In this case
the value is 0.15 mm.
Injection pump control rod
Depending on the engine model, the injection pump control rod will
link two, three, or four injectors to the engine governor.
Screws 1 and 2 are pivoted on the delivery control lever of each
‚ | pumpl/injector B, unscrew the screws and remove spring 3.
| When refitting tighten the screws 1 and 2 at a torque of 1,1 Nm
‘| and make sure that they stop on lever B of each pump/injector and
| not on rod A.
< To carry out the delivery equalisation of the injection pumps see
page 83.
= To carry out the timing of the injection pumps and speed
governor see page 95
Fuel rail
- (B) When removing the fuel feeding pumps A, with the rail holders B,
— \ NS pay attention that the sealing O-rings C remain in their seats.
O When refitting tighten the rail holder screws at a torque of 4 Nm.
-44 - FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06
Disassembly / Reassembly 4
Pump/injector unit - non-return valve
Non-return valve A immediately stops the engine whenever the stop
is activated.
Dimensions (mm):
LOW 502-602-803 - 1204
E D E
1,0+1,85 5,25+6,0 707,1
LDW 1204/7
В D E
0,551,415 5,95+6,5 7.0+7 1
Note: If the value of B is not achieved, the two rings C are not
subject to enough compression to ensure the seal; any fuel
loss would contaminate the lubrication oil and consequently
damage the engine, F = metal gasket.
Pump/injector unit - Disassembly
When the removal (but not replacement) of a unit injector is
required the following procedure may be used to avoid the need for
other adjustments:
Rotate the engine until the unit injector cam lobe 2 forces the cam
follower 1 to the highest position, then insert a suitable sized
(hardened) pin into the hole 3 and rotate the engine until the cam
follower 1 is at the lowest position. In this way the injection advance
regulator 4 remains calibrated.
Note: If you dismount more than one pump/injector unit, make
sure to reinstall them in the appropriate housing (with
relative drive rod 5); before mounting lubricate the drive rod
at its two ends with MOLYSLIP, AS COMPOUND 40 type.
Rocker arm assembly
Remove the nuts attaching the rocker arm assembly to the cylinder
head.
O When refitting tighten the nuts at a torque of 40 Nm.
The pin, that is hollow inside to allow lubrication, is closed at its
ends by two caps.
Note: The rocker arm assembly may be removed without removal
of the unit injectors.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06 - 45 -
Disassembly / Reassembly
Rocker arm pivot, dismounting and remounting
To remove pivot 1 from the support 2 it's necessary to drill out pin 3
using a 4mm drill bit.
On remounting insert a new pin and reinsert it in bearing surface A
(0 to 1 mm).
Check the rod's state of wear and tear (diam. B) and that of the
rocker arm holes (diam. C).
Remove the closing caps 4 at the end and carefully clean inside.
Dimensions (mm):
С-В
mm c-B limit value
A 0+1,00
17,989 + 18,000
0,015 + 0,041 0,090
с 18,015 + 18,030
Camshaft, disassembly
Loosen the screws and remove the cover 1.
Check gasket ring 2 for integrity.
Remove the drive rod from the fuel pump.
Gently remove the camshaft, slight rotations may be required to
avoid binding the camshaft lobes against the camshaft bearing
surface bores.
Note: The lift pump drive eccentric 3 is included on the flywheel end
of the camshaft and fixed with a screw.
O In case of replacement tighten the eccentric screw at a torque of 80
Nm.
Camshaft, journal and housing measurement
Use an inside micrometer gauge for housing diameters and an outside
micrometer gauge for journal diameters.
- 46 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
Camshaft journals and housings - Dimensions (mm)
А-В
А В А-В limit value
37,035 + 37,060 | 36,975 + 37,000 | 0,035 + 0,085 0,170
175
_ — ВЕ
= = 5
TO TW
[76
Note: The camshaft journal and cylinder head camshaft bore
dimensions are identical for all LDW-FOCS series engines
(LDW 502-602-702-903-1003-1204-1204/T-1404).
Camshaft lobe measurement
Use an outside micrometer gauge.
Intake / Exhaust / Injection camshaft lobe height - LDW 903
A1 = 1st cylinder intake camshaft lobe
A2 = 2nd cylinder intake camshaft lobe
A3 = 3rd cylinder intake camshaft lobe
М = 1st cylinder injection camshaft lobe
12 = 2nd cylinder injection camshaft lobe
13 = 3rd cylinder injection camshaft lobe
1st cylinder exhaust camshaft lobe
1st cylinder exhaust camshaft lobe
S3 = 1st cylinder exhaust camshaft lobe
H = 29,598+29,650 mm (intake/exhaust camshaft lobe height)
H1 = 28,948+29,000 mm (injection camshaft lobe height)
For 1204/T : H (intake) = 29,438+29,490 mm,
H (exhaust) = 29,778+29,830 mm.
All engines in the series (except LDW 1204/T) have intake exhaust
and injection cams with the same height of H and H1.
If wears on the cams exceeds by 0.1 mm the minimum value given
H and H1, replace the crankshaft.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 47 -
4 Disassembly / Reassembly
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CYLINDER HEAD, removal
deformation.
If cylinder head is deformed by more than 0.10 mm, level it off by
removing a maximum of 0.20 mm.
= For the cylinder head tightening procedure see page 57.
Valves
To remove the valves it is necessary to remove the collets; place a
spacer under the valve head, press strongly on the spring cap as
shown in the picture.
Components: 1 Valve stem
2 Valve stem seal ring
3 Spring seat
4 Spring
5 Spring cap
6 Collets
Valve stem sealing rings - Reassembly
To prevent deformation of the sealing ring 1 as it is inserted onto the
valve guide, insert it onto tool "7107-1460-047" 2 (after lubricating
the sealing ring) and proceed as shown int the picture ensuring that
gasket 1 is completely fitted.
Valve springs
Measure free height with a gauge.
Free height À = 46 mm.
Note: If the free height A is less than 43,5 mm replace the spring.
- 48 -
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06
Disassembly / Reassembly 4
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Valve, specifications
Exhaust valve A
Shaft and head are made of 2 different materials.
2 Welded joint
3 Chromium-plated joint
4 Portion made of: ........ X 45 Cr Si 8 UNI 3992
5 Portion made of: ........ X 70 Cr Mn NI N 216 UNI 3992
502-602-803-1204-1204/T | 702-1003-1404 ol
D 29,00 30,20 45° 30" + 45° 45
Intake valve B
Material: X 45 Cr Si 8 UNI 3992
1 = Chromium-plated joint
502-602-903-1204-1204/T | 702-1003-1404 ol
1
с 33,00 34,40 60° 30' + 60° 45°
Valve guides and valve guide housings
Both intake and exhasut valve guides are identical dimensionally and
are made from phosphoric gray iron with a pearlitic matrix:
Dimensions (mm):
A B G D Е
36,4+36,6 | 11,045+11,054 | 11,000+11,018 | 5,80+6,20 | 9,75+9,85
Note: Valve guides are supplied in finished form, further machining
is prohibited.
Valve guides with outside diameter B increased by 0.5 mm.
are available.
Valve guide insertion
Fit the guides with a punch taking account of value A in relation to
the cylinder head surface.
Dimensions (mm):
A B с
39,5 + 40,0 | 7,005 + 7,020 | 6,900 + 6,990
Clearance (mm):
(B-C) = 0,015+0,050 (B- C) limite usura = 0,10
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06 - 49 -
4 Disassembly / Reassembly
Valve seats and housings - Dimensions
— LOW 502-502-903-1204-1204/T
| mm O o
34 020+34 045
34,106+34,115
(ON
9 0 Ww >
44° 53" + 45° 59° 53' + 60°
Za A 4 30,020+30,041
~—C—| —A—| | =
D — B 30,108+30,116
LOW 702-1003 - 1404
a Uy mm ol o1
H 87
35,220+35,245
35,306+35,315
44° 53" + 45° 58° 53 + 60°
31,220+31 241
31,308+31,316
9,09 >
Press valve seats into the housings
Note: Valve seatsare supplied in finished form, further machining is
rohibited.
Valve recess and seat sealing width
Dimensions (mm):
LOW 502-502-303-1204-1204/T
mm
0,5+0,8 1,1
S 1,6+1,7 2,0
LOW 702 - 1003 - 1404
mm
0,7+1,0 1,3
1,6 2,0
Grind valve seats with fine emery paste.
After grinding check the valve recess D relative to the cylinder head
surface and the seat sealing width S.
- 50 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Disassembly / Reassembly
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Pre-combustion chamber
Components:
1 Pre-combustion chamber
2 Pre-heating glow plug
3 Pre-combustion chamber ring nut
4 Cylinder head
The pre-combustion chamber does not normally require removal or
service, if service is necessary follow the procedure described below.
Pre-combustion chamber ring nut removal
The pre-combustion chamber is fixed to the cylinder head by a ring
nut, so before removing the pre-combustion chamber it is necessary
to unscrew the pre-combustion chamber ring nut.
Use the special tool "7107-1460-027" 1 to romve the ring nut 2.
Pre-combustion chamber, removal
Before proceeding with removing the pre-combustion chamber it is
necessary to remove the pre-heating glow plug.
Screw special tool "7107-1460-030" 1 into the pre-combustion
chamber.
Carefully, but sharply, slide the slide hammer 2 up the special tool
shaft until contact is made with end of the tool. The hammer effect of
the special tool will extract the pre-combustion chamber 3.
Note: There are many types of precombustion chambers for the
various engines described as follows.
- LDW 502
- LDW 602-903-1204-1204/T.
- LDW 702-1003-1404.
Pre-combustion chamber, installation
The pre-combustion chamber has a hole on the side where the pre-
heating glow plug 2 must be inserted.
When re-fitting introduce the the new pre-combustion chamber into
the cylinder head so that the side hole of the pre-combustion
chamber aligns with the glow-plug hole.
To make sure that both the holes align appropriately use tool "7107-
1460-031" 1 inserting it into the glow-plug hole.
O Tighten the ring nut twice:
1st tighten at a torque of 100 Nm,
2nd tighten at a torque of 180 Nm.
Chack that clearance A is 3,68+4,1 mm.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 51 -
4 Disassembly / Reassembly
101 102
Oil pan, removal
- The used engine oil can cause skin
in contact for prolonged periods.
- If contact with oil cannot be avoided, wash carefully your
hands with water and soap as soon as possible.
- Do not disperse the oil in the ambient, as it has a high
pollution power.
-cancer if kept frequently
Remove the fixing screws.
Insert a spacer 1 in the forward and rear main bearings.
Detach the silicon from the main bearing rubber bulb seals.
When re-mounting apply Silicone *
in the picture.
" Dow Corning 7091" as shown
O Tighten the screws at a torque of 10 Nm.
Before starting the engine make sure that:
1) the oil drain plug is tightened correctly
2) the engine has been refilled with the prescribed quantity of oil (see
page 26).
PISTON
Remove the connecting rod big end cap.
Remove the piston-connecting rod assembly.
Note: The LDW 502’s piston is different from the LDW 602 in
terms of its combustion chamber.
The LDW 1204/T piston is different from that of the LDW
1204 in term of its cooling nozzle's slot bleed and an insert
in the first section's hollow.
The Ricardo type of combustion chamber is used for LDW
702-1003-1404 engines.
Stop pin rings, dismounting and remounting
Extract the ring inserting a pointed tool in hollow A.
On remounting, insert rings with the points turned downwards inside
the corners ( a = 15”).
- 52 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
Piston, disassembly and inspection
Remove the stop rings and remove the pin, see fig. 101.
Remove the piston rings and clean the slot.
Measure diameter Q at height A from the base of skirt (A = 9 mm).
If the diameter is worn more than the 0.05 mm minimum given
value, replace piston and rings.
Note: The provided oversize elements are of 0.50 mm and 1.00 mm
№ 7 £2—
7
SUN
` ay
Lr
= J
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103
Piston, class
The pistons are subdivided according to their diameters into categories: A, B, C. These references, are shown on the top of
the piston (see fig. 100).
LOW 502-602-903-1204-1204/T
Class O Cylinder - mm O Piston - mm Clearance - mm
A 71,990+72,000 71,930+71,840
B 72,000+72,010 71,940+71,850 0,050+0,070
с 72,010+72,020 71,950+71,960
LDW 702-1003 - 1404
Class @ Cylinder - mm O Piston - mm Clearance - mm
A 74,990+75,000 74,330+74,340
B 75,000+75,010 74,940+74 950 0,050+0,070
с 75,010+75,020 74,950+74,960
Piston supply:
Pistons at the nominal diameter are only supplied in category A.
Pistons oversized by 0.50 and 1.00 mm are supplied with reference to the increased level on the piston crown:
O 72.5 - O 73 for LDW 502-602-906-1204-1204/T engines and © 75.5 — 76.0 for LDW 702-1003-1404 engines.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 53 -
Disassembly / Reassembly
Piston, weight
Weigh pistons when replacing them in order to avoid unbalance.
104
- Piston rings - End gaps (mm)
| _ | _ Place piston rings squarely into the unworn part of the lower cylinder
в | и and measure the end gap A.
- O Cb
о oo (C—
Oo (FF Piston ring A limit value
| C0 1° 0,25+0,45
O
© 2° 0,25+0.45 1.0
— 9 Z—
— SS 3° 0,20+0,45
Ё /
RN /
105 — -
Piston ring, Clearance between grooves (mm)
A
B A 0,090+0,125
C
0.050+0,085
с 0,040+0,075
106 107
- 54 - FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06
Disassembly / Reassembly 4
Piston ring, mounting order
A = 1° ring (internal tapered and torsional)
B = 2° ring (internal tapered and torsional)
C = 3° Oil control ring
D = Chrome-plated area
E = Chrome-plated area
Note: When there is writing on the surface of a piston ring, mount
that surface with face upward.
Piston, assembly
and conncecting rod big end bearing.
Couple the piston to the connecting rod inserting the pin, after
lubricating it, just via thumb pressure.
Insert the two pin stop rings and check that they are properly
housed in their seats, see fig. 101.
Using piston ring compression pliers, introduce the piston into the
cylinder so that combustion chamber A is directly under the
precombustion chamber parallel to the head.
Couple the piston/connecting rod to the crankshaft.
109
< For tightening the head/connecting rod see fig. 115-116.
Piston clearance
/ JY N= UT The piston in the TDC (top dead centre) position may extend or be
7 - short of the upper surface of the cylinder.
Co) QU Determinare the clearance of each piston using a dial indicator to
I] measure the difference between the two surfaces (piston crown and
NH upper cylinder surface).
| To determine the piston clearance and, by consequence, which
AN copper gaske is most suitable it is necessary to consider the A value
| >> = of the piston that projects furthest.
Nr So
A NE <=? < <=
NY <
HE
IR
=
111
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 55 -
Disassembly / Reassembly
Head gasket
covering only when you are going to mount it.
The gasket thickness is identified by the number of notches located
in point B.
Choose the appropriate gasket considering that each A value on
the table corresponds to a gasket with: no hole, one hole, two
holes, or for the 1404 one notch, two notches, three notches.
The A value relates to figure 111.
Each time you dismount the head you must replace the gasket.
112
LDW 502-602-903
A (mm) N° of holes Piston clearance
0.97+1.06 0 holes
0.39+0.48
1.07+1.16 1 hole
1.17+1.25 2 holes 0.40+0.48
LOW 19204 -1204/T
A (mm) N° of holes Piston clearance
0.97+1.06 1 hole
0.39+0.48
1.07+1.16 2 holes
1.17+1.25 3 holes > A 0.40+0.48
LDW 702-1003
A (mm) N° of holes Piston clearance
0.82+0.91 1 hole
0.54+0.63
0.90+1.01 2 holes
1.02+1.10 3 holes Dm 0.55+0.63
LOW 1404
A (mm) N° of notches Piston clearance
0.82+0.91 1 notch
0.52+0.61
0.92+1.01 2 notches
1.02+1.10 3 notches 0.53+0.61
- 56 - FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06
Disassembly / Reassembly 4
114
115
Cylinder head assembly
Use a torque wrench equipped with a device for angular tightening.
Measure the length of each screw (normal length = 89.5+90.5 mm).
Replace it if it exceeds 92 mm.
Proceed as follows.
Cylinder head tightening procedure LDW 502-602-702-903-1003
retightened except if it is disassembled again.
Before mounting it is advisable to lubricate stem, shank and
underhead of screws with SPARTAN SAE 460 oil.
A = For LDW 502-602-702 models
B = For LDW 903-1003 models
Following the numerical order shown in the diagram, the bolts must
be tightened in three phases:
1st phase = 50 Nm
2" phase = Rotate the wrench 90° in a clockwise direction.
3rd phase = Rotate the wrench again 90° in a clockwise direction.
For LDW 502 with pressure cast (aluminium) crankcase:
With head H tightening bolts: 1st phase = 60 Nm
With head 8.8 tightening bolts: 1%t phase = 40 Nm
2" phase = Eseguire una rotazione
della chiave in senso
orario di 90°.
3 phase = Proseguire con una
rotazione della chiave in
senso orario di 90°.
Cylinder head tightening procedure LDW 1204-1204/T-1404
Following the numerical order shown in the diagram, the bolts must
be tightened in three phases:
1st phase = 50 Nm
2" phase = Rotate the wrench 90° in a clockwise direction.
3rd phase = Rotate the wrench again 90° in a clockwise direction.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 57 -
Disassembly / Reassembly
CONNECTING ROD
While reassembling the big end bearings, we suggest cleaning
all parts thoroughly, as well as proper greasing in order to
avoid risks of seizure at the first start.
Big end bearing
After connecting rod from crankshaft disconnection, check the
following.
While reassembling, be sure the two centring notches A an B are
on the same side.
O Tighten the connecting rod big end cap screws simultaneously at
a torque of 40 Nm.
Note: The big end bearing is supplied both at the nominal value
and undersized by 0.25 and 0.50 mm.
In the LDW 502 engine with light alloy crankcase the
connecting rod is aluminium type and not provided with
connecting rod big end bearing and small end bush.
Connecting tod, weight
Weigh connecting rods when replacing them in order to avoid
unbalance.
The difference in weight should not exceed 10 g.
The difference in weight of the pre-assembled connecting rod, piston
and pin must not exceed 14 g.
Connecting rod with bearings and pin
Dimensions (mm):
A= 126,48+126,52
106,98+107,02 ..... (for LDW 502)
В = 18,015+18,025
= 20,015+20,025..... (for LDW 702-1003-1204/T-1404)
С = 40,021+40,050 ..... (bearing tightened at 40 Nm)
D = 17,996+18,000
= 19,996-20,000 (for LDW 702-1003-1204/T-1404)
E = 50,900+51,100
54,000+55,100 ..... (for LDW 702-1003-1204/T-1404)
(B-D) = 0,015+0,039 (B-D) limit value = 0,060
Nota: When driving the small end bearing make sure both oilholes
are aligned.
- 58 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
ИИ ОЙ)
И i X
la. — D— |
fs Y Z
122 123
124
E 7
7 7
7 7 Z
7 y Z
4 Z 7 55"
y Z 7 ll 45:55
ß % 7 й ~~
7 7 CA
| В
ZA
125
Connecting rod alignment
Utilizzare un calibro con piano di riscontro o un comparatore come
in figura.
Controllare lallineamento degli assi utilizzando lo spinotto del
pistone; lo scarto A = 0,015 mm;. limite 0,030 mm.
Piccole deformazioni si possono correggere sotto una pressa
agendo con sforzi graduali.
CYLINDERS
Reset the dial gauge with a calibrated ring: check the diameter D in
points 1, 2 and 3; repeat the same operation rotating the dial gauge
by 90° at the same heights.
Check any wear in zone X where the piston rings operate and if it is
greater than the 0.05 mm max limit given adjust the cylinder to the
next increased value.
72,000 mm for LDW 502-602-903-1204-1204/T engines;
75,000 mm for LDW 702-1003-1404 engines.
Cylinder, class
The pistons (A, B, C) locations are shown on the piston crown
while those for the cylinders are found on the crankcase in the
points shown by the arrows, see picture.
Note: For LDW 502 with an aluminium crankcase, the cast iron
cylinders can be adjusted normally to increase values by 0.5
and 1.0 mm.
The cylinders are not to be changed.
Cylinder roughness
cloth.
The angle of the crossed processing marks must be between 45°
and 55°. These must be uniform and distinct in both directions.
Average roughness must be between 0.5 and 1 pm.
The whole surface of the cylinder affected by contact with the piston
rings must be rendered with the plateau method.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 59 -
Disassembly / Reassembly
©]
©
O
126
Central main bearing caps
The central support caps are marked with locations that can be
numbers as in the diagram or dots.
The same locations are given on the crankcase.
Couple the caps with the same references and on the same side. In
any case locate the bearing's two centring notches that are to be
found on the same side.
O Tighten the screws simultaneously at a torque of 60 Nm.
Rear and forward main bearing caps
levels with a ground bar
On remounting the rear main bearing cap 1 replace the lateral
rubber gaskets 2, keeping in mind that projections A and B of the
support must be 0,5+1,0 mm; cut off any exceeding portions.
Do the same with the front bearing cap.
Before reintroducing the bearings in the crankcase, place between
their surfaces two plates C and D - 0.1 mm thick - se.no.7107-
1460-053.
O Tighten the screws at a torque of 60 Nm.
Note: It is advisable to apply a few drops of silicon sealant on the
surface of the gasket slot 2.
Check the clearances between the bearings and the journal
Use the "Perfect Circle Plastigage” type calibrated wire A and put it
at the centre of the bearing with a bit of grease.
O Tighten the screws at a torque of 60 Nm.
Find out the clearance value checking the wire's compression with
the appropriate graduated scale supplied in the same pack and
available on the market.
& For clearance values between the journals, connecting rod pin
and the relevant bearings see page 64.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
SA
131
| 435 |
135
Piston coolant nozzles
The piston has a recess so that during up-down movements
and vice versa it cannot come into contact with the nozzle.
When remounting the nozzle be careful that it is placed so that
when the piston goes past it is in the centre of the recess.
They are in the supercharged LDW 1204/T engine and are housed
near the main bearings.
Components:
1 Washer
2 Nozzle
3 Washer
4 Joint (tighten to 12Nm)
5 Valve (opening pressure = 1+1.2 bar)
6 Spring
Characteristics (mm):
A B G D o
0,80+0,85 34 150 16 5°
Shoulder half rings
So as to keep them in their seats during assembly, put a bit of
grease.
The half-rings must be assembled with the slots A as in the figure.
Thickness of half-rings is equal to 2.31+2.36 mm.
They are supplied as spare parts as increased thickness 0.1 and 0.2
mm, see below.
Crankshaft axial clearance
After tightening the main bearings measure the axial clearance A
between the crankshaft flywheel side shoulder and the main bearing
half rings.
Ref. Clearance Limit value
A mm 0,130+0,313 0,5
B mm 23,05+23,10 23,50
If the clearance is not within the given value check value B.
If need be, fit oversized half rings, see below.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 61 -
Disassembly / Reassembly
138
Shoulder half rings, oversized elements
Dimensions (mm):
с B* A
Std 22,787+22,920 | 23,050+23,100
1 22,987+23,120 | 23,250+23,300
0,130+0,313
2: 3,087+23220 23,350+23,400
3 23,187+23,320 23,450+23,500
* A of Fig. 134.
** B of Fig. 135.
Grinding B as per relevant table, you can mount the following half
rings:
1st Oversized element Half rings 1 and 2 + 0.10 mm on both sides
of the bearing
2" Oversized element Half rings 1 and 2 + 0.10 mm on one side
of the support and + 0.20 mm on the other
side.
3 Oversized element Half rings 1 and 2 + 0.20 mm on both sides
of the bearing.
Crankshaft front and back oil seal rings
An ambient temperature below -35°C may damage the rings.
The front oil seal ring 1 inserted into the oil pump cover and the back
one 2, in the flywheel side flange.
If warped, hardened, or cracked, replace them.
For the replacement:
- Carefully clean the housing
- Keep the ring immersed in engine oil for about half an hour.
- Drive it into its housing with a buffer exercising a uniform pressure
on the whole front surface. Be sure that the two surfaces A and B
meet on the same level.
- Refill the interior hollow with grease and lubricate the seal lip with
thickened oil.
Note: Before major engine overhaul, in case of oil leakage in the
seal area of rings 3 and 4, you can remedy this by replacing
the rings and pushing them about 2 mm deeper with respect
to the previous ones.
If the rings are black it means zones 3 and 4 of the crankshaft
are tempered. In this case it is necessary to remount a ring of
the same colour.
If the rings are brown it means that zones 3 and 4 of the
crankshaft are not tempered. In this case it is necessary to
remount brown coloured rings.
- 62 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
142
Crankshaft, lubrication lines
wear protective goggles.
A = Crankshaft LDW 502
B = Crankshaft LDW 602-702
Put the crankshaft in a bath of crude oil.
Remove the caps and clean lines 1 and 2 or 3 and 4 with a bit;
blow with compressed air.
Reposition the new caps in their seating and check the seal.
Note: The LDW 502 crankshaft with aluminium crankcase is not
interchangeable with the cast iron crankcase, having
different counterweights.
Crankshaft, check journals and crank
Use a micrometer for the outsides.
Journal and connecting rod pins diameters
Dimensions (mm): LDW 502 - 602 - 903 - 1204 - 1204/T
Ref. Tolerance Limit value
A (mm) | 47,984+48,000 47,900
B (mm) 39,984-40 000 39,900
LDW 702-1003 - 1404
Ref. Tolerance Limit value
À (mm) | 50,981=51,000 50,900
В (тт) 39,984+40.000 39,900
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 63 -
4 Disassembly / Reassembly
143
Main bearings and connecting rod big ends diameters
Dimensions (mm):
LDW 502 - 602 - 903 - 1204 - 1204/7
Ref. Tolerance
C (mm) | 48,016+47,984 48,055
D (mm) | 40,021+40,050 40,100
LDW 702 - 1003 - 1404
Ref. Tolerance
C (mm) | 51,023+51,059 51,098
D (mm) 40,021+40,050 40,100
The dimensions given refer to tightened bearings.
< For tightening torque see figures 116 e 126.
Clearances between the bearings and corresponding pins
See figures. 143 = 144.
Dimensions (mm):
LOW 502 - 602 - 903 - 1204 - 1204/7
Ref. Clearance Limit value
C-A{mm) | 0,022+0,074 0,200
0-3 (mm) | 0,021+0,066 0,130
LDW 702 - 1003 - 1404
144
Ref. Clearance Limit value
C-A (mm) | 0,023-0,078 0,200
О-В (тип) | 0,021-0,066 0,130
Nota: Both for crankshaft bearings and for connecting rod big end
bearings internal diameter are undersized by 0.25 and 0.50
mm.
- 64 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Disassembly / Reassembly 4
Hydraulic pump drive
A = Third drive
You can mount a 2P hydraulic pump on the third drive with Bosch
flanging, or a 1 PD type one.
You can draw 7 KW of power from the third drive corresponding to a
37 Nm torque at 3600 rpm (engine revolutions).
Drive ratio, engine revs/pump revs = 1:0.5.
Third drive, components
1 Splined sleeve
2 Toothed pinion
3 Seal ring
4 Flange for 1 PD hydraulic pump
5 Seal ring
Note: Sleeve 1 also includes the fuel pump control cam and is
fastened with the same standard cam screw, with a tightening
torque of 80 Nm + 90°.
O Tighten pinion 2 to the hydraulic pump at 45 Nm
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 65 -
149
TURBO CHARGER
Only the LDW 1204/T is supplied with the turbocharger.
The LDW 1204/T is available in two versions:
TD 025 03C 2.8 for 3600 r/min
TD 025 03C 2.0 for 3000 r/min.
Turbocharger components
1 Waste gate tube
2 Attuatore
3 Collare
4 Corpo turbina
5 Anello seeger
6 Chiocciola compressore
7 Spessore
8 Dado
9 Controdado
10 Albero con turbina
11 Segmento
12 Parafiamma
13 Cuscinetto
14 Seeger
15 Spessore
16 Segmento
17 Deflettore olio
18 Manicotto reggispinta
19 O-ring
20 Cuscinetto reggispinta
21 Anello reggispinta
22 Cuscinetto
23 Anello seeger
24 Anello seeger
25 Supporto cuscinetti
Turbocharger pressure testing
Install a 0-2bar pressure gauge at position A after removing the
existing plug.
Start the engine and operate at low idle for five minutes to allow
warm-up.
Increase the engine speed to 3000 r/min or 3600 r/min (depending
on engine specification while applying full Nb load to the engine).
= See page 10 for the power output curve.
The gauge pressure, at full speed, full load, should be 0.87-0.91 bar
(655-685 mm Hg).
If the pressure setting does not reach specification, adjust the
turbocharger waste gate 8 as is defined on page 48.
- 66 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Turbocharger 5
Turbocharger west gate adjustment - Regolazione corsa asta
comando valvola " Waste gate "
Disconnect westgate tube 7 from the turbocharger compressor side.
Using a T-joint connect a pressure gauge 4 (scale 0 to 2 bar) and
with the compressed air network pipe complete with reducer 5.
The network air supply pressure must be from 1.5 to 2 bar.
Make a hole B in the pressure gauge pipe of 1.55 mm in diameter.
This will help bleeding some air and stabilizing pressure in the
pressure gauge.
Set up a dial gauge (6) so that the feeler is rested on terminal 2.
Via the pressure reducer 5 convey some air to the actuator so as
terminal 2 is pushed forwards by A (A=1 mm).
The pressure read in the pressure gauge must be 830+890 mm Hg
(1.11+1.19 bar).
If the pressure is lower than the given value proceed as follows.
Unscrew locknut 1.
Remove split pin 9 and disconnect rod 8, “waste gate” control valve.
Keeping the rod steady tighten terminal 2 until you reach the
calibration pressure.
During the rotation of terminal 2, the rod should not undergo any
torsion.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 67 -
- The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil
because its combustion may lead to a sharp increase in the rotation speed.
- Use suitable oil in order to protect the engine.
Nothing more than lubrication oil can influence the performances and life of an engine.
- Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause
the piston rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts.
Engine life will also be notably reduced.
- The oil viscosity must suit the ambient temperature in which the engine operates.
Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time.
Wear protective gloves to avoid touching used oil.
If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible.
Dispose of old oil in the correct way as it is highly polluting.
151
Components:
1 Pressure gauge 9 Oil filler cap
2 Rocker shaft 10 Camshaft
3 Connecting rod pin 11 Oil pressure regulating valve
4 Oil filter cartridge 12 Oil pump
5 Journal 13 Crankshaft
6 Oil drain plug 14 Oil suction filter
7 Oil dipstick 15 Turbosupercharger with corresponding pipes only fitted in LDW 1204/T models.
8 Bleed
- 68 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Lubrification circuit 6
U
Nu
0
2
155
Internal oil filter and oil sump return pipe
Clean with petrol the internal oil filter 1 and oil sump return pipe 2,
blow also some compressed air.
Replace sealing rings 3 and 4.
O Tighten oil drain plug at a torque of 40 Nm.
Oil pump
The oil pump mounted on LDW 502-602-903 engines has a lower
delivery rate than that mounted on LDW 1204-1204/T engines.
Oil pump delivery test at 1000 revs per minute with an oil temperature
of 120°C.
Engine Delivery (1/17) Pressure (bar)
502-602-702-903-1003 44.3
3+3,5
1204-1204/1-1404 6+6,5
Delivery test at 3600 rpm with an oil temperature of 120°C.
Engine Delivery (1/1) Pressure (bar)
502-602-702-903-1003 19,3
4+4 5
1204-1204/1-1404 28,5
Oil pump, clearance between rotors
Measure the clearance A between teeth as in figure; the maximum
value is 0.171 mm.
Clearance wear limit should be 0.250 mm.
< See page 42 for assembly and disassembly.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 69 -
6 Lubrification circuit
{im
Oil pressure regulating valve
Components:
1 Valve
2 Spring
3 Gasket
4 Screw cap
Spring length = 27.50+27.75 mm
Blow the valve's seating with compressed air and carefully clean all
the components before remounting them.
Nota: The valve begins to open at a pressure of 4.5+5.5 bar.
156
Oil filter cartridge
Components:
1 Gasket
CARTUCCIA CAR
' 2 Plate
(Los, 3 Rubber element
y 5 Filtering element
6 By-pass valve
7 Spring
Characteristics:
157 Maximum operating pressure: ..................... ee... 7 bar
Maximum bursting pressure: 20 bar
Degree of filtration: ......................... eee. 15H
By-pass valve calibration: ......................e.ee.eee..... 1,5+1,7 bar
Total filtration surface: ....................eeeeeeeeeee 730 cm*
Total filtration surface for LDW 1204 engine: ..... 1450 cm“.
Oil pressure check
Once remounted fill the engine with oil, fuel and coolant.
Remove the pressure switch, fit a union and connect a 10 bar
pressure gauge.
Start the engine and check how pressure is affected by oll
temperature.
Nota: With a maximum operating temperature of 120°C at 900 rpm
the oil pressure must not be less than 1 bar.
158
- 70- FOCS Workshop Manual cod. 1.5302.351 7° ed_ rev. 06
Lubrification circuit
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 71 -
p . ngine has cooled down and, also in that case, open
the radiator cap or expansion tank plug with caution.
- When there is an electric fan do not approach a hot engine because it could also come on with the engine off.
- The liquid coolant is a pollutant and therefore must be disposed of with care according to environmental
provisions.
159
Components:
1) Coolant filler plug 6) Circulation pump
2) Compensating tank 7) Fan
3) Thermostatic valve 8) Radiator
4) Cylinder block 9) Heat exchanger with relevant pipes. Only fitted in LDW 1204/T engine.
5) Thermostat for liquid temperature indicator
- 72 - FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06
Coolant circuit 7
A
ZL x Го
# SS NT
7 )Q
Yo”
162
Radiator and compensation, check and seal tank cap.
Remove the cap from compensation tank cap and check that the
liquid is at the correct level.
Replace the cap with a new one provided with hand air pump
socket.
Compress air at a pressure of 1 bar for about two minutes.
Check that there are no drips in the radiator.
The tank cap is supplied with a vacuum relief valve 1 and an
overpressure valve 2.
Overpressure valve opening pressure of 0.7 bar.
Coolant circulation pump, components
1 Rotor
2 Front seal gasket
3 Pump casing
4 Exhaust hole
5 Bearing
6 Pulley
7 Shaft
Note: The pump for LDW 1204-1204/T-1404 engines is different
from the one of the other series (fig. 148) due to the
presence of a ring between rotor 1 and gasket 2.
Thermostatic valve
1 - Stainless steel or brass casing
2 - Wax bulb
3 - Air relief hole
Characteristics:
Opening temperature: ........ 83°+87°C
Max stroke at: .................... 94°C = 7 mm
Liquid recycling: 30=80 l/h,
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 73 -
(CARTUCCIA *
Rica hi
ES
167
Fuel feeding / injection circuit
Components: 1 Fuel Tank
2 Fuel filter
3 Fuel feeding tube
4 Fuel lift pump
5 Injection pump
6 Injector
7 Fuel rail passage rubber joint
8 Injector exhaust pipe
9 Fuel tank cap
10 Solenoid valve
Note: The tank complete with filter is supplied on request.
Fuel filter detached from the tank (on request)
1 Air relief valve
2 Bearing
3 Cartridge
4 Rubber element
5 Filtering element
Cartridge characteristics:
Filtering paper: ........................._... PF 905
Filtering surface: 2400 cm?
Degree of filtration: .......................... 2:31
Maximum operating pressure: ........ 4 bar
< See page 24 for periodic maintenance details.
Fuel lift pump
Components:
1 Fuel lift pump
2 Push rod
3 Seal ring
| The fuel pump is membrane type. It is driven by camshaft cam via
| a drive rod.
It is equipped with an external manual fuel lever.
Characteristics:
With the control cam at 1500 rpm the delivery rate is 75 I/hours and
the self-adjusting pressure is at 0.55 to 0.65 bar.
Fuel pump drive rod projection
The protrusion A of drive rod 2 from the cylinder head surface is
1.66+2.18 mm.
The check must be carried out with cam 1 idle as in the figure.
O Block the two fuel pump fastening nuts simultaneously at 24 Nm.
Check the length of the drive rod and if it is not the right size,
replace it.
Drive rod length = 153.15+153.35 mm.
- 74 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Fuel system 8
Pump/injector unit
Designed by LOMBARDINI, the pump/injector is exclusive to FOCS
series engines.
The injection system includes two, three, four identical pumps/
injector units, each one of which feeds a cylinder.
Note: On pumps/injector units of recent construction (for serial
numbers and references see the table on page 78) the pump
@ has been modified (see fig. 174).
IS] Following to this modification and others like the elimination
of cap 20 of fig. 169 the method of checking the static
injection advance has changed as well, fig. 187-188 as that of
injector setting, fig. 178.
т
5
С
G
>
|
y
\ NU
Te
À
CD
e
169
Pump/injector unit, components
1 Seeger ring A Ring nut
2 Tappet B O-ring
3 Stop plate C Nozzle
4 Plunger D Spacer
5 Spring E Pressure rod
6 Screw F Spring
7 Bearing G Spacer
8 Lever I Casing
9 Ring nut L Control spiral
10 Plunger guide O-ring M Plunger guide
11 Cylinder
12 Delivery valve
13 Gasket
14 Spring
15 Filler
16 Pin O When remounting the injector tighten ring nut A at 70 Nm
17 O-ring
18 Non-return valve
19 O-ring
20 Cap screw (old type)
21 Metal gasket (new type)
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 75 -
8 | Fuel system
Plunger barrel ring nut assembly/disassembly
To disassemble ring nut 9 fig. 169, use the suitable wrench A se.no.
“| 7107-1460-029
O When refitting tighten it a torque of 34 Nm.
Injection pump assembly/disassembly
Disassemble the unit following the progressive order of fig. 169.
Reassemble following the same steps in reverse order.
During reassembly, turn the plunger spiral L towards the non-return
valve 19, as follows.
171
Plunger injection pump reassembly
To be able to insert the plunger in its barrel press with a finger and
at the same time slowly rotate lever 8 fig. 171 until guide M of the
plunger fig. 172 enters the lever seating.
Note: If by mistake the plunger is mounted with the spiral in the
wrong direction the pump won't function (there is no danger
| that the engine runs away).
|;
)
172
- 76 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Fuel system
173
N——
——
I
— MI
WW
Fm
a
—
a
e 117
Pumping element (old-type injection pump)
1 Plunger
2 Upper plunger section
3 Plunger barrel
4 Delay notch
5 Control slot
Dimensions (mm):
5,5
nominal value
2,00 + 2,03
inlet hole diameter
1,50 + 1,53
outlet hole diameter
10,00
mi ooo mor
9,6
F 0,7
Pumping element
1 Plunger
2 Upper plunger section
3 Plunger barrel
4 Delay notch
5 Control slot
INJECTION Dimensions
PUMP
A В с D
502
Aluminium
crankcase
6590.307 | 55
1.50 | 1.50 | 9.965
502-602 + + +
0590.285 | 6.0 |
903-1204 1.551 1.53 | 10.035
1204/T
702-1003-1404 6590.290
6.5
9.505
9.635
0.9
Pump/injector unit se.no. 6590.285 control data.
1 Delivery control lever on stop position.
2 Delivery control lever on maximum delivery position.
Rod stroke form max delivery
position (mm) Rpm (*)
mm?3/stroke
9,5
3600
19+23
9,5
1200
15-24
start position
300
35+38
Injector setting pressure: 140+155 bar
* Rpm rating is that of the crankshaft.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 77 -
8 | Fuel system
REFERENCE NUMBER
HIGH PREASSURE HOLE
ETERNA
= нее
re
paar Mana
OFFSET HOLES
LOCATING PEG
OLD TYPE INJECTOR PUMP INTERMEDIATE INJECTOR PUMP CURRENT PUMP INJECTOR
176
Lombardini injection system is being steadily implemented, seeking the best performance of its engines.
For this reason the pump injector body has been modified three times in the course of its evolution.
Three different pump injectors are shown in the top figure.
Old type injector pump: it is characterised by its high pressure hole
Intermediate injector pump: is characterised by not having the high pressure hole (the hole can be there but it is only used
to control the injector and injection advance) and by the locating peg between inlet and outlet
holes.
Current pump injector: it is characterised by its offset inlet and outlet holes. These are also oversized, due to the
absence of the high pressure hole.
REFERENCE o INJECTION
Ne CODEN ENGINE TYPE ADVANCE VALUE SPECIAL TOOLS
ADVANCE 1460.028 + 1460.024
231-2 6590.262 502 - 602 - 903 - 1204 11° - 13° INJECTOR SETTING ........ 1460.028
TD.Coeeee a, 1460.048
ADVANCE 1460.028 + 1460.024
272-0 6590.283 502 MINI CAR 11° - 13° INJECTOR SETTING ........ 1460.028
TDC. oii, 1460.048
ADVANCE 1460.028 + 1460.024
235-2 6590.235 1204/T 4° - 6° INJECTOR SETTING ........ 1460.028
TDC... 1460.048
ADVANCE 1460.056
272 6590.272 502 - 602 - 903 - 1204 8° - 10° INJECTOR SETTING ........ 1460.028
T.D.C..........................….….……… 1460.048
272-1 6590.285 502 - 602 - 903 - 1204 8° - 10° < 2999 g/min ADVANCE / INJECTOR SETTING. ........ 1460.074
12° - 14° > 3000 g/min T.D.C..............eeeeeeeeeeeeeeeereeereoereoeoeoenenen<<. 1460.048
272- 6590.286 502 MINI CAR 11° - 13° ADVANCE / INJECTOR SETTING ........ 1460.074
272+ 6590.307 TDG 1460.048
235-4 6590.290 1204/T 6°-8° ADVANCE / INJECTOR SETTING ........ 1460.074
235-4 6590.287 TD.Coo e ee EEE RER R EEE E EEE E EG 1460.048
235-3 8°+10° < 2999 g/min ¡ADVANCE / INJECTOR SETTING........ 1460.074
235-4 6590.290 702 - 1003 - 1404 12° + 14° 3000+3600 g/min [T.D.C......... nn 1460.048
13° + 14° > 3600 g/min
- 78 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Fuel system 8
Injector, setting (old type)
Connect the injector to a hand pump after removing cap screw 20
fig. 169.
By means of the tool - se.no. 7107-1460-028 - check that the
setting pressure is 130+145 bar.
Adjust, if necessary, by changing the spacer located under the
spring.
There are eleven different spare part spacers from 1 to 2 mm.
When you replace the spring, the setting should be made at a
pressure higher than 10 bar to compensate for adjustments in
… Operation.
1 Check the needle seal by slowly actuating the hand pump for 10
: seconds, until you reach abt. 130 bar.
1 If the nozzle drips, replace it.
Setting of injector according to current pump/injector unit
Remove the non-return valve leaving its metal gasket and fit a cap
screw in its place, that is part of tooling 7107-1460-074.
Mount then head 1 and coupling 2.
Then connect a hand pump as shown in the picture.
The pressure setting must be 140-155 mm bar.
Injector, nozzle projection
To avoid excessive compression of the spark arrester A, fig. 181,
check projection B of the nozzle fig. 179.
B = 6.80+7.05 mm.
If this measure is larger put spacer 2 between ring nut 1 and copper
gasket 3.
0.25 mm thick spacers are available.
Injector, spark arrester
Every time you remove the pump/injector you must replace the
spark arrester, the copper gasket, the oil O-ring, as well as the 2 fuel
O-rings.
Insert the spark arrester in the injector housing with surface A
pointing upwards.
O Tighten simultaneously both nuts that fasten it to the head at 20
Nm.
For engines with the injectors fixed with self-locking nuts, tighten
the nuts at 23 Nm.
< See page 24 for periodic maintenance details.
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 79 -
Fuel system
Injection advance control and regulation
Dismount the rocker arm cover, see page 40.
Position the device on the head, in contact with cylinder no. 1.
Mount the dial gauge on the valve controlled by tool ref. 1460.048.
Via lever 1 of the tool, open the valve until it comes into contact
with the piston.
Then rotate the crankshaft until the TDC is read in the dial gauge.
Then reset the hundredths.
Remove the fuel pipes.
Remove the O-ring in contact with the non-return valve and
replace it with the appropriate gasket - equipment component part
ref. 1460.074. Once the check has been completed, remove the
gasket and refit the O-ring.
Connect tool 1460.074 on pump n° 1. This will automatically
position the control lever to the maximum delivery. The tool is
provided with 3+4 couplings for connection to a tank that must be
not lower than 30 cm from the pumps level. Coupling 2 is
equipped with a plastic pipe with internal drip collecting wire.
Put cylinder 1 under compression and open the tank tap. Fuel
diesel will start to flow out from coupling 2.
Slowly rotate the engine towards TDC 1 until the diesel fuel stops
leaking out.
At this point with lever 1 (of fig. 182) move again the valve until it
touches the piston and read on the dial gauge how many
hundredths are missing from the previously reset value (TDC).
To convert hundredths into degrees, consult the table below.
Repeat the operation on the other cylinders.
Injection advance for currently used pump/injector unit
LDW 502 LDW 602-903-1204-1204/T | LDW 702-1003-1404
o (mm) (mm) (mm)
18° 1.947 2.367 2.468
17° 1.739 2.115 2.205 Engine Code Reference n* Rpm o
16° 1.543 1.876 1.956
; ; ; 502-602 . Ano
15 1.358 1.651 1.721 903-1204 6590-285 272-1 1500-2999 8°+10
14° 1.184 1.440 1.501
- ; 502-602 6.4 A0
13 1.022 1.242 1.296 903-1204 6590-285 272-1 > 3000 12-14
12° 0.871 1.059 1.105
11% | oras 0 891 0930 502 6590-307 272+ 3000-3600 10°+12
109606 0.737 0.769 foe 6590-290 235-4 1500+2999 | 8°+10°
g° 0.491 0.597 0.623
8 0386 472 0499 foe 6590-290 235-4 3000+3600 | 12°+14°
7° 0.297 0.362 0.378
5° 0.218 0.266 0.277 702-1003 6590-290 2354 > +3600 13°54 5°
1404
1204/7 6590-290 235-4 1500+3600 6°+8°
* With aluminuim crankcase
- 80 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Fuel system
— ТО)
| КС
=I LE
if)
NID, Ô
Static injection advance tuning
If the injection advance value found does not correspond to the
previously described value, adjust the screw E and repeat the test.
Rotating screw E by % turn will change the injection advance by 5°.
If turned clockwise, injection is advanced.
In the opposite direction, injection is delayed.
Injection advance references on timing belt protector
The method of checking injection advance is essentially the same as
that described in fig. 182 with one difference: instead of using the
device se.no. 7107-1460-048 with which you measure piston
lowering with respect to the Top Dead Centre, you use references A
and C on the timing belt protector and reference D located on engine
pulley.
When D coincides with A the piston has reached its TDC.
When D coincides with C the piston is in injection advance position.
TDC (Top Dead Center) references
D coincides with A = TDC of 1% cylinder of all series engines, of 4
cylinder LDW 1204-1204/T-1404, and of 2"
cylinder LDW 502.
E coincides with A = TDC of the 2"? cylinder LDW 903-1003.
F coincides with A = TDC of 2nd cylinder LDW 602-702., of 3"
and 2" cylinder LDW 1204-1204/T-1404.
G coincides with A = TDC of 3" cylinder LDW 903-1003.
Note: Following the arrow’s rotation direction, the combustion
order for LDW 903-1003 is D, G, E (1st - 3" - 2" cylinder
respectively. As to LDW 1204-1204/T-1404 the sequence is
D, F, D, F (15— 3-4" and 2" cylinder).
Tester and special coupling for injection advance control (Old-
type injection pump)
1 Special coupling. Serial number: 7107-1460-028
2 Injection advance tester. Serial number: 7271-1460-024.
Remove the cap on the pump/injector casing and in its place screw
on coupling 1.
On this coupling tighten the tester 2.
Note: When reassembling the cap on the pump/injector unit, check
Its seal.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 81 -
Fuel system
Static injection advance regulation
Fill the tank and operate the fuel pump.
| Set the pump/injector delivery control rod (ref. A fig. 187) at half-
stroke.
Bring the piston to the top dead centre of compression. Fit a 13
mm hexagon wrench on the injection advance adjusting screw lock
nut. By turning the wrench forth and back you prime the injection
pump, thus enabling the tester to be drained.
With the piston at its TDC, operate lever 2 fig. 188 and bring the
drain valve into contact with the piston. Then reset dial gauge.
Go back % of a turn moving the crankshaft anticlockwise. Then
turn forward again very slowly
observing the fuel level inside the tester. As soon as the level
changes, then stop. You reached the static injection advance.
By actuating lever 2 check piston lowering with respect to the TDC
that shall be between 0.89 and 1.24 mm for LDW 602-903-1204,
and between 0.73 and 1.02 for LDW 502 engine model.
The table on page 80 shows both piston lowering expressed in mm,
with respect to the TDC, and the corresponding rotation of the
crankshaft, expressed in degrees.
The static injection advance in degrees a = 11° to 13° refers to all
engines for adjustments from 1500 / 3600 rpm.
Preliminary steps to pumpl/injector unit delivery balancing test
Closing the oilhole
To perform this test you must remove the rocker arms cover and
close hole 1 with an M 8x1.25 or M 10x1.5 screw (on latest model
engines) not longer than 8 mm. Also remove the copper gasket.
If the camshaft and rocker arms are dry, lubricate them with engine
oil.
Note: If you only want to check the nozzle it is not necessary to
balance the deliveries; provided that when you dismount the
rod you do not loosen adjusting screws 1 and 2 (fig. 193).
Test head B assembly
Remove fuel pipe A and mount one test head B in its place per
pump/injector.
The test heads complete with pipes are supplied together with
instrument ref. 7104-1460-069.
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Fuel system 8
Instrument connection
Place the instrument 1, se.no. 7104-1460-127 at least 20 cm above
the pump/injector level.
Connect pipe A (outlet from every instrument test piece) with pipe A
(inlet of every pump/injector) and pipe B (return to the instrument)
with pipe B (outlet from the pump/injector).
Open tap 2 and 3 of each pipe and fill the instrument with diesel.
Start the engine and bring it to 1500 rpm idle running.
Close the fuel supply to the engine from the instrument's tank using
lever 4 and after 1 minute observe the levels in the test piece.
If a level goes down more than the others it is necessary to decrease
the delivery of the corresponding pump (see below) and vice versa
+ to increase the delivery if the level increases.
Injection pumps delivery balancing
In case the balancing error read on the test pieces is greater than 2
cm?/min, then injection pumps deliveries should be adjusted.
Plate 4 and rod 3 are blocked by screws 1 and 2. Loosen them.
Move plate 4 rightwards with respect to rod 3 if you want to
increase delivery.
If moved leftwards delivery decreases. Make very small movements
with the plate.
O Tighten screws 1 and 2 at a torque of 1,1 Nm.
Note: Each time a pump/injector is replaced it is necessary to
balance the deliveries.
FOCS Workshop Manual cod. 1.5302.351 7° ed_ rev. 06 - 83 -
10
20 ———— |
30
40
50
60
ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP
BLACK
(UPON REQUEST)
BLUE
|
)
RED
ORANGE
BLACK
PURPLE
RED
70
GRAY
80
WHITE
90
GREEN A,
100
110
120
130
140
LIGHT BLUE
BROWN
YELLOW
FUEL
SOLENOID
BLACK
BLUE
PINK
|
ALTERNATOR
CONNECTOR
STARTING
MOTOR
GLOW-PLUGS
Г BATTERY CONNECTION
sil
EXCITATION TERMINAL
a
12V BATT.
-ON CONNECTION
AIR FILTER RESTRICTION
COOLANT TEMP.
SENDING UNIT
INDICATOR
LOW FUEL SWITCH
х
< LEVEL SWITCH
a
BLACK
LOW OIL PRESSURE
COOLANT
TEMP.THERMISTOR
(FOR GLOW TIMER/
= RELAY)
COOLANT HIGH
TEMP. SWITCH
[x [f=] [BE [O
Re TADA EST
= ae
ee Пенн
5
AUXILIARY TERMINALS
4 |(+) Positive pole under key (6.3)
12 |(-) Negative pole - Earth (6.3)
2 |Signal for temp. water instrument (4.75)
10 | Signal for electric rev. counter (4.75)
Oil pressure signal (4.75)
Protected socket available (4.75)
7
6
5 Protected socket available (4.75)
9
Rear connection — Jumper with 6 for alternator protection
Control panel auxiliary terminals 2, 4, 5, 6, 7, 10 and 12 are also accessible from
the front, under the fuse access door.
- 84 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Electric System 9
194
1000 2000 3000 4000 5000 6000 7000
Giri/1'
195
Alternator, Iskra 14V 33A
Nominal voltage ................. 14V
Nominal current output ...... 33A
Maximum Rpm .................. 12.000 giri/1'
Maximum peak Rpm ......... 13.000 gliri/1'
Voltage regulator AER 1503
Rotation (viewed at puley end): Clockwise
O Tighten nut 1 at a torque of 35-45 Nm.
Alternator, Iskra 14V 33A - Performance Curve
The curve was obtained at room temperature of +25°C with 13 V
battery voltage.
Note: The rpm shown on the table are referred to the alternator.
Engine rpm/alternator rpm ratio, with driving pulley diameter
88 mm = 1:1.23
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 85 -
9 | Electric System
RED
4mm (502-802) BLUE
8mm(903-1204)
2.5mm}
=
o
35 mm?
—BROWN ==
30 À (502-602)
SOA (903)
80 À (1204) 8
A al 4 ar
4 mm’ Г К
iia JL
m?
J
Electric starting layout (12V) with Iskra alternator 14V 33A
1 Alternator
2 Starter Motor
3 Battery
4 Glow Plugs
5 Coolant temperature thermistor
6 Glow Plug Controller / Timer
7 Key Switch
8 System Fuse, 30A for LDW 502-602-702; 50 A for LDW 903-
1003; 80 A for LDW 1204-1204/T-1404.
9 Fuse (Accessory)- 5A
10 Fuel Solenoid Valve
11 Glow Plug Indicator Lamp
12 Coolant High Temperature Lamp
13 Coolant High Temperature Switch
14 Oil Pressure (Low) Lamp
15 Oil Pressure Switch
16 Alternator Charging Lamp
17 Air Filter High Restriction Indicator Lamp
18 Air Filter Restriction Switch
19 Low Fuel Level Lamp
20 Low Fuel Level Switch
A Accessory Position
В Off Position
C On Position
D Starting Position
Note: Battery 3 not supplied by LOMBARDINI.
For assembly we recommend a battery with the following
characteristics, see table below.
H -duty starti diti
Normal starting conditions eavy (max allowed). Hons
Engine type Starter motor class Rapid discharge Rapid discharge
(epicyclic type) Kw Capacity intensity Capacity intensity
K20 - Ah (DIN Standards at K20 - Ah (DIN Standards at
-18° C) À -18° C) À
1,2 44 210 66 300
502
1,1 44 210 66 300
1,1 44 210 66 300
602-702
1,6 66 300 88 330
1,1 44 210 66 300
903-1003
1,6 66 310 88 330
1,1 44 210 66 300
1204-1404
1,6 66 300 88 330
1,1 55 255 66 300
1204/7
1.6 66 300 88 330
- 86 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Electric System 9
Alternator, Marelli type AA 125 R 14V 45A
Characteristics:
Nominal voltage ee = 14V
Nominal current output ................——————... = 45A
Maximum ROM …....….......…....….ccccrrrcccrecers = 14000 giri/1'
Maximum peak Rpm (for 15") .................. = 15000 giri/1'
Bearing, Pulley End .................—.e..=eeeee_—... = 6203-27
Bearing, Voltage Regulator End ............... = 6201-2Z/C3
Voltage regulator ....................———...._____—_—— =RTT 119 A
Rotation (viewed at puley end): Clockwise
Note: Use only high temperature grease when servicing bearings
O Tighten nut 1 at a torque of 60 Nm.
Alternator, Marelli type AA 125 R 14V 45A - Performance Curve
The curve was obtained at room temperature of +25°C with a costant
13 V battery voltage.
P1 = Power Output (KW)
| = Current Output (Amps)
T = Efficiency
Note: The RPM shown is that of the alternator. The value of the
rom axis must be multiplied by 1000.
Alternator speed is a function of engine speed and the
crankshaft pulley diameter. If the engine pulley is 88 mm,
then the alternator speed ration is 1.3:1. If the engine pulley
is 108 mm, then the alternator speed ratio is 1.6 : 1.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Giri/1"
198
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 87 -
9 | Electric System
11
10 BLACK
(392-602)
A о
199
Electric starting layout (12V) with Marelli type АА 125 R 14V 45A
alternator
1 Alternator
2 Starter Motor
3 Battery
4 Glow Plugs
5 Coolant temperature thermistor
6 Glow Plug Controller / Timer
7 Key Switch
8 System Fuse, 30A for LDW 502-602-702; 50 A for LDW 903-
1003; 80 A for LDW 1204-1204/T-1404.
9 Fuse (Accessory)- 5A
10 Fuel Solenoid Valve
11 Glow Plug Indicator Lamp
12 Coolant High Temperature Lamp
14 Oil Pressure (Low) Lamp
15 Oil Pressure Switch
16 Alternator Charging Lamp
17 Diode
18 Air Filter Restriction Switch
19 Air Filter Restriction Switch
20 Low Fuel Level Lamp
21 Low Fuel Level Switch
A Accessory Position
В Off Position
C On Position
D Starting Position
Note: Battery 3 not supplied by LOMBARDINI, for battery
characteristics see page 89.
Flywheel Alternator
12V 20A with three cables at output
12V 30A with two cables at output
1 Flywheel
2 Ring gear
3 Magnet ring (Rotor)
4 Stator
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Electric System 9
Alternator battery charger curve 12V 20A
(three cables at output)
This curve is obtained at 20°C.
The statistical charging output of the flywheel alternator is +10% to -
5% of the values shown.
KA)
1000 1500 2000 2500 3000 3500 4000
Giri/d"
201
Alternator battery charger curve 12V 30A
(two cables at output)
This curve is obtained at 20°C.
The statistical charging output of the flywheel alternator is +10% to -
5% of the values shown.
Giri/1'
202
FOCS Workshop Manual cod. 1.5302.351 7° ed_ rev. 06 - 89 -
Electric System
203
ED YELLOW
|
4 mm°(502-602)
6 mm°(903-1204)
Electric starting layout (12V) with flywheel alternator
1 Alternator
2 Starter Motor
3 Battery
4 Glow Plugs
5 Coolant temperature thermistor
6 Glow Plug Controller / Timer
7 Key Switch
8 System Fuse, 40A
9 Fuse (Accessory)- 5A
10 Fuel Solenoid Valve
11 Glow Plug Indicator Lamp
12 Coolant Hign Temperature Lamp
13 Coolant High Temperature Switch
14 Oil Pressure (Low) Lamp
15 Oil Pressure Switch
16 Alternator Charging Lamp
17 Voltage regulator
18 Air Filter High Restriction Indicator Lamp
19 Air Filter Restriction Switch
20 Low Fuel Level Lamp
21 Low Fuel Level Switch
A Accessory Position
B Off Position
C On Position
D Starting Position
Note: Battery 3 not supplied by LOMBARDINI.
Voltage regulator connections
AETSA Cable Conncetion dimensions
SAPRISA DUCATI
R B colour | |
| NICSA Width Thickness
| me Yellow G 6,35 0,8
R Red R 9,50 1,2
+ Red B 9,50 1,2
LE Green L 4,75 0,5
00 Brown C 6,25 0,8
204 205
- 90 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Electric System 9
206
i MiNm) UCV
Ag PO Mn)
70007 1.47 287
65007 1.31 267
6000+ 1.2} 247
55007 1.4 227
50007 1.07 207
45001 .H 187
40001 BT 167
3500+ JT 147
3000} 61 12
25004 5} 101
20004 4} af
15004 3} 64
10004 .24 4
5004 + 2
+ of 04
207
208
STARTER MOTOR - Bosch DW 12V 1,1 KW
Rotation: Clockwise
A = 17,5+19,5 mm
(distance from starter mounting flange to ring gear face)
Note: Please refer to your local BOSCH distributor for service parts,
repair criterion and warranty service.
Starter motor, Bosch DW 12V 1,1 KW - Performance Curve
The curve was obtained at room temperature of -20°C with a fully
charged 66Ah battery.
U = Starter Motor Voltag
n = Armature r/min
| = Absorbed Amperage
P = Starter Output Power (KW)
M = Starter Output Torque (Nm)
Starter motor, Bosch 12V 1,6 Kw
Rotation: Clockwise
A = 29,50+31,5 mm
(distance from starter mounting flange to ring gear face)
Note: Please refer to your local BOSCH distributor for service parts,
repair criterion and warranty service.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 91 -
9 | Electric System
n{1/min) P{W) M{Nm)
30007 3.07 307
28007 281 28+
25007 2.61 26+
24001 24+ +
22004 224 224
20004 20+ 20+
1800+ 181 18+
16001 1.61 161
13007 141+ 141
12004 1.24 121
1000+ 1.0+ 101
и
* 25309
tar beng |
Starter motor, Bosch DW 12V 1,6 KW - Performance Curve
The curve was obtained at room temperature of -20°C with a fully
charged 88 Ah battery.
U = Starter Motor Voltag
n = Armature r/min
| = Absorbed Amperage
P = Starter Output Power (KW)
M = Starter Output Torque (Nm)
Pre-heating glow plug
Characteristics:
Nominal voltage esse 12,5V
Current absorption .................. e... 12A+14A after 5 seconds
Sheath surface temperature ..................... 850°C after 5 seconds.
Components:
1 Sheath
2 Primary Heating Со!
3 Secondary Heating Coll
O When remounting tighten at a torque of 20 Nm.
Pre-heating plug control unit with coolant temperature sensor
To avoid white smoke immediately following start-up post-heat for
about 5 seconds, see table
(sec.)
Resistance Coolant temp. | pre-heat Post-heat
(ohm) C
7000 -20 23.5+29.5
2400 0 13.5-16.5
100 +20 8.5-10.5 A070
212 460 +40 6.0+8.0
< 320 +50 Heating stop
< For electrical connections see figures 196-199-203.
- 92 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Electric System 9
7
2
| TE
215
Temperature sensor for control unit
In engines fitted with the above-mentioned type of control unit, the
introduction of the glow plugs depends on a temperature sensor that
varies preheating temperature in relation to the coolant temperature.
Characteristics:
Temperature range ............... -30 = +50°С
Voltage range .................————.—. 6-24 V
Temperature max. ................ 150°C
Max. tightening torque. ......... 30 Nm.
Oil pressure switch (Fig. 215)
Characteristics:
Opening pressure: 0,15+0,45 bar (for gen-sets: 1,4 bar).
O Tightening torque 25 Nm.
Coolant high temperature lamp sensor (Fig. 216)
Characteristics:
CirCUIt eee eee single pole
Voltage range... 6+24 V
Max. Power Absorption.................. 3 W
Closing temperature ...................... 107=113°C
O Tightening torque 25 Nm.
FOCS Workshop Manual cod. 1.5302.351 7° ed_ rev. 06 - 93 -
SPEED SETTINGS
Setting the idle minimum (standard)
After filling the engine with oil, fuel and coolant, start it and let it
3 warm up for 10 minutes.
Turn the screw 1 to adjust the idle speed at 850 to 900 rpm.
Tighten then the locknut.
Note: If you loosen screw 1 speed decreases. To the opposite
direction speed increases.
Setting the idle maximum (standard)
/| After setting the idle speed turn screw 2 and regulate the idle
maximum at 3800 rpm.
Block then the locknut.
When the engine reaches its setting power, the maximum rpm will
| stabilise at 3600 rpm.
Note: If you loosen screw 2 speed increases.
To the opposite direction speed decreases.
Pump injection delivery standard setting without
dynamometric brake
This adjustment must be performed with the dynamometric braked
engine.
Without this the regulation is approximate.
In this case proceed as follows:
- Unlock the maximum flow limiter lock nut.
- Fully screw in flow limiter C.
- Run the engine to the maximum speed, that is 3800 rpm.
- Loosen flow limiter C until the engine revs start to decrease.
- Screw flow limiter C by 2.5 turns.
- Tighten the lock nut.
Note: If the engine under maximum load emits too much smoke
unscrew C. Tighten C if at this load there is no smoke and if
the engine does not reach its maximum power.
- 94 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Settings 10
Injection pump flow limiter and engine torque gearing device
Flow limiter C has the function of limiting the injection pump’s
maximum delivery.
The same mechanism acts also as a torque gearing device.
Indeed, under torque, spring N operating lever L overcomes the
resistance of spring M located in the plunger barrel.
The stroke H that the torque gearing device allows to be carried out
by lever L, will increase the injection pump delivery and the torque
will hit its maximum value.
The stroke H varies depending on which engine torque gearing
device is fitted on the engine.
Setting the stop
Remove the rocker arms cover and completely unloosen screw B.
Push rod A to the right and keep it in this position; see figure.
Tighten screw B until it touches rod A.
Release rod A and tighten again screw B by a 0.5+1.0 turn.
Tighten the lock nut.
Pump/injector unit timing with speed governor
- Loosen the screws C of each pump/injector unit.
- If it is not connected, connect spring D to rod A (with this
operation the speed governor blocks are closed).
- Move plates B of each pump/injector unit rightwards; see figure
(with this operation the pumps/injector unit are at their maximum
delivery).
- Tighten screws C at 1.1 Nm. Re-balance the deliveries.
Note: Spring D is the start-up fuel supplement spring: with the
engine stopped pull rod A to the right by bringing the pump/
injector unit delivery to the maximum value, until the speed
governor comes into operation with the engine running
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 95 -
10
224
Required settings (as most commonly applies)
Pump/injector unit delivery setting with braked engine
1) Run the engine to the maximum speed.
2) Screw flow limiter C (see fig. 219).
3) Load the engine up to the power and number of revs required by
the applications manufacturer.
4) Check that consumption is within the values allowed for in the
settings table (see below).
If consumption is not within the given figures, it is necessary to
change the balance conditions shown to the brake, altering the
load and the speed governor. Redo the consumption check on the
stabilised engine.
5) Unscrew limiter C until the engine rpm start to decrease. Lock the
limiter using the lock nut.
6) Completely release the brake and check the rpm at which the
engine stabilises.
The performance of the speed governor must meet the class
required by the application's manufacturer.
7) Stop the engine.
8) Recheck the valve clearance with the engine cold.
* Refers to power curve NB, see pages 18+20 and after run-in.
Power* re .
( NB curve ) Specific fuel consumption
Engine Rpm .
Time (sec) per
Kw 100 cm? g/Kwh
2200 5,51 192+183 285+299
502
3600 7,72 120+115 326+340
2200 7,35 155+147 265+279
602
3600 9,92 93-89 326-340
2200 11,08 105+99 261+274
903
3600 15,06 60-58 328-342
2200 14,78 79+75 258+272
1204
3600 20,22 45,8+44 326+340
1204/7 3600 29,50 36+35 284+290
- 96 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Settings 10
E.G.R. calibration
Mount a T-branch on vacuum valve - E.G.R. valve connection pipe
(1), and connect it to a vacuum pressure gauge with 1 bar bottom
scale so as to be able to read the degree of vacuum within the pipe.
Note: It is also possible to use a mercury column, 1 metre long,
since the maximum suction pressure exerted by the vacuum
pump is 720 mmHg.
Adjust the position of the accelerator lever via the regulator block, so
that the internal adjusting nut (2), is about 5 mm from the end of the
thread.
Accelerate the engine up to 3.600 rpm (with valve closed: this
means that the value showed on the vacuum pressure gauge or on
the mercury column should be O.
In case it is different from zero, adjust the regulator block nuts to
move it, in relation to the rod (3), in the direction that goes from the
flywheel to the timing.
With the brake at a braking curve N=constant, “load” the engine
slowing it down to 2.800 rpm.
Acting on the accelerator look for the E.G.R. valve closing point
(pressure of the vacuum pressure gauge or mercury gauge equal to
zero).
Note: Pay attention to determine the precise closing point: by
slightly accelerating the engine the vacuum value in the
E.G.R. operation pipe should immediately increase.
Measure the engine consumption in order to calculate the mm3/
stroke value.
If the calculated value is less than 18.8 mm3/stroke, adjust the
adjusting nut making it closer to the end of the rod (3) to “increase
the calibration”.
When the required value of 18.8 mm?/stroke has been reached (and
a power of around 7 KW) tighten the adjusting nuts.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 97 -
- If the engine is not to be used for long periods, check the storage environment, the type of packaging and make sure these
conditions will allow proper maintenance. If necessary, cover the engine with protective sheeting.
- Do not store the engine directly on the ground, in damp environments, in areas exposed to the elements, near sources of
danger, including less visible hazards such as high-voltage power lines, etc.
, it is necessary to apply protective measures that are valid for 6
months (see “Protective treatment”).
If, after the first 6 months, the engine is still not to be used, it is necessary to carry out further measures to extend the
protection period (see “Protective treatment”).
1 - Check that the engine oil and coolant are up to level.
2 - Fill up with fuel containing 10% AGIP RUSTIA NT
3 - Run the engine at minimum idle speed for 15 minutes.
4 - Switch off the engine.
5 - Remove the lubrication oil.
6 - Fill the sump with protective oil: AGIP RUSTIA C.
7 - Start the engine and check for fuel and oil leaks.
8 - Bring the engine to % of the maximum speed for 5-10 minutes.
9 - Switch off the engine.
10 - Empty the fuel tank completely.
11 - Spray SAE 10W oil on the exhaust and intake manifolds.
12 - Close all openings to prevent foreign bodies from entering.
13 - Thoroughly clean all external parts of the engine using suitable products.
14 - Treat non-painted parts with protective products (AGIP RUSTIA 100/F).
15 - Loosen the alternator/fan belt.
16 - If necessary, cover the engine with protective sheeting.
In countries in which AGIP products are not available, find an equivalent product.
AGIP RUSTIA NT: MIL-L-21260 P10, grade 2
AGIP RUSTIA C: MIL-L-644-P9
AGIP RUSTIA 100/F: MIL-C-16173D.
After a year of engine inactivity, the coolant loses its properties and must be replaced.
- 98 - FOCS Workshop Manual cod. 1.6302.351 7° ed rev. 06
Storage 11
After a period of inactivity and before installing and running the engine, it is necessary to carry out a few measures in order to
ensure that it runs at maximum efficiency.
1 -
2 -
3 -
4 -
5-
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
Remove the protective sheeting.
Eliminate any blockages in the exhaust and intake ducts.
Use a cloth soaked in degreasing product to remove the external protective treatment.
Remove the intake manifold.
Inject lubrication oil (no more than 2 cm?) into the valves and install the intake manifold.
Adjust the alternator/fan belt tension.
Turn the flywheel manually to check the movement of the mechanical parts.
Refill the tank with fresh fuel.
Start the engine and run at % of the maximum speed for 5-10 minutes.
Switch off the engine.
Remove the protective oil to replace with engine oil.
Introduce new oil (see “Lubricants”) up to the correct level marked on the dipstick.
Replace the filters (air, oil, fuel) with original spare parts.
Empty the cooling circuit completely and pour in the new coolant up to the correct level.
Over time, a number of engine components and lubricants lose their properties, even when the engine is not in use,
and so it is important to consider whether they need replacing, based not only on the mileage, but also on age and wear.
Install the engine and make the necessary connections and unions.
Make sure that electrical contacts are intact and efficient.
Check that the engine oil and coolant are up to level.
Start the engine and keep at minimum speed for a few minutes.
Check for leaks and, if necessary, find and eliminate the cause.
Switch off the engine.
Double check that the engine oil and coolant are up to level.
FOCS Workshop Manual cod. 1.5302.351 7° ed rev. 06 - 99 -
POSITION
In control rod
Con rod ****
Union for the nozzle 1
filter cartridge (M 20x1,5 union)
screws
arm cover
n
pan
Camshaft bearing su
ug nuts
pump n
n
n
un nut
arm assembly su
cam
side oil seal ri
Pre-combustion chamber ri
acuum pum screws
Belt tensioner
m
| re switch
drain
xx
See page 57
ck
Riference
(figure and page n°)
62+63 - p. 44
116 - p. 58
131+132 - p. 61
210+211 - p. 92
22+24 - p. 34
34 - p. 37
215 - p. 93
152+153 - р. 69
113+115 - р. 57
21 - р. 34
Aluminium connecting rod with 35 Nm tightening torque.
Diam. & pitch
( mm )
M
8x1
20X1,5
6
6x1
M 10
M 6
M 6
5x0,8
8x1,5
M 10
8x1
M8
M 10
30x1,5
10
12x1,5
6x1
16x1,5 sin.
10x1
12x1,5
18
TCEI 4x1,5
10x1,5
Sealant
270
270
638
Silicon
Tighten the two nuts that fasten each pump/injector unit at the same time. For engines with the injectors fixed with self-
locking nuts, tighten the nuts at 23 Nm.
Tighten these in two phases: the first phase at 100 Nm, the second phase at 180 Nm. See page 51, figures 95-96.
- 100 -
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06
SALER OO Torque specifications and use of sealant | 12
Table of tightening torques for standard screws (coarse thread)
Quality/
Dimensions E" т E
R>400N/mm* R>500 R>600N/mm? | R>800N/mm? | R>1000N/mm? | R>1200N/mm?
Diameter Nm Nm Nm Nm Nm Nm Nm
M3 0,5 0,7 0,6 1 1,4 1,9 2,3
M4 1,1 1,5 1,4 2,2 2,9 4,1 4,9
M5 2,3 3 2,8 3,8 4,5 6 8,5 10
M6 3,8 5 4,7 6,3 7,5 10 14 17
M8 9,4 13 12 16 19 25 35 41
M10 18 25 23 31 37 49 69 83
M12 32 43 40 54 65 86 120 145
M14 51 68 63 84 101 135 190 230
M16 79 105 98 131 158 210 295 355
M18 109 145 135 181 218 290 405 485
M20 154 205 193 256 308 410 580 690
M22 206 275 260 344 413 550 780 930
M24 266 355 333 444 533 710 1000 1200
M27 394 525 500 656 788 1050 1500 1800
M30 544 725 680 906 1088 1450 2000 2400
Table of tightening torques for standard screws (fine thread)
Quality/
Dimensions = = = =
R>600N/mm? | R>800N/mm? | R>1000N/mm? | R>1200N/mm?
Diameter Nm Nm Nm Nm
M 8x1 20 27 38 45
M 10x1 42 56 79 95
M 10x1,25 39 52 73 88
M 12x1,25 71 95 135 160
M 12x1,5 68 90 125 150
M 14x1,5 113 150 210 250
M 16x1,5 84 113 105 141 169 225 315 380
M 18x1,5 122 163 153 203 244 325 460 550
M 18x2 117 157 147 196 235 313 440 530
M 20x1,5 173 230 213 288 345 460 640 770
M 20x2 164 218 204 273 327 436 615 740
M 22x1,5 229 305 287 381 458 610 860 1050
M 24x2 293 390 367 488 585 780 1100 1300
M 27x2 431 575 533 719 863 1150 1600 1950
M 30x2 600 800 750 1000 1200 1600 2250 2700
FOCS Workshop Manual cod. 1.5302.351_7° ed_ rev. 06 - 101 -
Injection pumps delivery balancing
instrument
7107-1460-127
Precombustion chamber extractor
7107-1460-030
Injection pump static injection advance
tester(old type)
7271-1460-024
Sheet metal for insertion of main bearings in
the crankcase
7107-1460-053
Ring nut wrench for fastening pump/injector
pumping element
7107-1460-029
Precombustion chamber wrench
7107-1460-027
Precombustion chamber adjusting rod
7107-1460-031
Coupling for static injection advance control
and setting of old-type injection pumps
injector
7107-1460-028
Device for mounting valve guide gasket,
intake and exhaust side
7107-1460-047
Valve lowering device for injection advance
control
7107-1460-048
Timing belt tightening tool
7107-1460-049
Crankshaft clamping tool
7107-1460-051
Tool for injection advance control and setting
of injector for pump/injector unit: se.no.
6590-272
7107-1460-056
Tool for injection advance control and setting
of injector for pump/injector unit: se.no.
6590-285, 6590-307, 6590-290
7107-1460-074
- 102 -
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
Notes
FOCS Workshop Manual cod. 1.5302.351_7% ed rev. 06
- 103 -
- 104 - Manuale officina FOCS cod. 1.5302.350 7° ed rev. 06
.
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